Compressors and methods for use

ABSTRACT

A compressor suitable for use in a portable oxygen concentrator. In one exemplary embodiment, the compressor includes a crankshaft rotatable about a central axis and a plurality of diaphragm assemblies spaced apart around the central axis generally within a plane. The diaphragm assemblies include diaphragms movably mounted to respective housings to at least partially define chambers. A plurality of rods extend between respective diaphragms and the crankshaft. The rods are coupled to the crankshaft such that the rods are offset axially from one another along the central axis and are coupled to the diaphragms for cyclically increasing and decreasing pressure within the chambers as the crankshaft rotates about the central axis.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) fromprovisional U.S. patent application Nos. 60/788,916, filed Apr. 3, 2006;60/744,196, filed Apr. 3, 2006; 60/744,197 filed Apr. 3, 2006;60/744,271, filed Apr. 4, 2006; and 60/744,272, filed Apr. 4, 2006, thecontents of each of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to compressors, to portableoxygen concentrators including compressors, and methods for making andusing compressors, e.g., to compress air drawn into oxygenconcentrators, and to methods for making and using oxygen concentrators.

DESCRIPTION OF THE RELATED ART

Lung diseased patients often need supplemental oxygen to improve theircomfort and/or quality of life. Stationary sources of oxygen areavailable, e.g., oxygen lines in hospitals or other facilities, that mayprovide oxygen to patients. To allow some mobility, cylinders of pureand/or concentrated oxygen can be provided that a patient may carry orotherwise take with them, e.g., on pull-along carts. Such cylinders,however, have limited volume and are large and heavy, limiting thepatient's mobility.

Portable devices have been suggested that concentrate oxygen fromambient air to provide supplemental oxygen. For example, pressure swingadsorption (“PSA”) apparatus are known that separate nitrogen fromambient air, delivering a stream of concentrated oxygen that may bestored in a tank or delivered directly to patients. For example, U.S.Pat. Nos. 5,531,807; 6,520,176; and 6,764,534 disclose portable PSAoxygen concentrators. Accordingly, apparatus and methods for providingoxygen would be useful.

U.S. Publication No. 2005/0072298 discloses a portable oxygenconcentrator that includes a non-reciprocating compressor, specificallya scroll compressor Is disclosed in U.S. Pat. Nos. 5,759,020 and5,632,612. U.S. Pat. No. 5,730,778 discloses a rotary valve andcompressor system for use in an oxygen concentrator. Accordingly,compressors, e.g., for use in portable oxygen concentrators, would beuseful.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide acompressor that, in one exemplary embodiment, includes a crankshaftrotatable about a central axis and a plurality of diaphragm assembliesspaced apart around the central axis generally within a plane. Thediaphragm assemblies include diaphragms movably mounted to respectivehousings to at least partially define chambers. A plurality of rodsextend between respective diaphragms and the crankshaft. The rods arecoupled to the crankshaft such that the rods are offset axially from oneanother along the central axis and are coupled to the diaphragms forcyclically increasing and decreasing pressure within the chambers as thecrankshaft rotates about the central axis.

In exemplary embodiments, the compressor may weigh not more than abouttwo pounds, may have a maximum pressure output from the heads of abouttwenty pounds per square inch (20 psi), may have a volume less thanabout one hundred seventy cubic inches (170 in³), and/or may have afootprint of not more than about thirty six square inches (36 in²).

In one embodiment, the motor may include a base plate and the heads maybe fixed to the base plate. The heads may include bottom surfaces andinput and output ports communicating with the chambers, the input andoutput ports extending from the bottom surfaces. For example, the bottomsurfaces may define a bottom plane, and the input and output ports mayextend from the bottom plane for connecting the input and output portsto an air manifold, thereby directly securing the diaphragm assembliesto the air manifold.

In accordance with another embodiment, a compressor is provided thatincludes a motor including an output shaft defining a central axis, acrankshaft rotatably coupled to the output shaft such that rotation ofthe output shaft causes the crankshaft to rotate eccentrically relativeto the central axis, three heads spaced apart around the central axis,and three rods extending between respective heads and the crankshaftsuch that rotation of the crankshaft displaces the rods transverselyrelative to the axis for cyclically drawing ambient air into anddelivering compressed air out of the heads on a cyclical basis.

In exemplary embodiments, the heads may be diaphragm assemblies orpiston assemblies. The heads may be substantially coplanar with oneanother, and the rods may be coupled to the crankshaft such that therods are offset axially from one another along the central axis.

In accordance with still another embodiment, a compressor is providedthat includes a motor comprising an output shaft defining a centralaxis, a crankshaft rotatably coupled to the output shaft such thatrotation of the output shaft causes the crankshaft to rotateeccentrically relative to the central axis, (2N+1) diaphragm assembliesspaced apart around the central axis, the diaphragm assembliescomprising diaphragms movably mounted to respective housings to at leastpartially define chambers, and (2N+1) rods extending between respectivediaphragms and the crankshaft such that rotation of the crankshaftdisplaces the rods transversely relative to the central axis for movingthe diaphragms relative to the housing to cyclically increase anddecrease pressure within the chambers, wherein N is an integer greaterthan zero (0).

In accordance with yet another embodiment, a portable oxygenconcentrator is provided that includes a plurality of sieve beds foradsorbing nitrogen from air, the sieve beds comprising air inlet/outletends and oxygen inlet/outlet ends, at least one reservoir communicatingwith the oxygen inlet/outlet ends of the sieve beds for storing oxygenexiting from the oxygen inlet/outlet ends of the sieve beds, acompressor for delivering air at one or more desired pressures to theair inlet/outlet ends of the sieve beds, the compressor comprising amotor coupled to a crankshaft defining a central axis, the compressorincludes three heads spaced apart around the central axis and rodsextending between respective heads and the crankshaft

These and other objects, features, and characteristics of the presentinvention, as well as the methods of operation and functions of therelated elements of structure and the combination of parts and economiesof manufacture, will become more apparent upon consideration of thefollowing description and the appended claims with reference to theaccompanying drawings, all of which form a part of this specification,wherein like reference numerals designate corresponding parts in thevarious figures. It is to be expressly understood, however, that thedrawings are for the purpose of illustration and description only andare not intended as a definition of the limits of the invention. As usedin the specification and in the claims, the singular form of “a”, an and“the” include plural referents unless the context clearly dictatesotherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are top and bottom perspective views, respectively, of afirst embodiment of a portable oxygen concentrator apparatus accordingto the principles of the present invention;

FIG. 2 is an exploded perspective view of the apparatus of FIGS. 1A and1B;

FIG. 3 is a schematic diagram of the apparatus of FIGS. 1A and 1B;

FIG. 4 is a cross-section of an exemplary sieve bed suitable for use inthe apparatus of FIGS. 1A and 1B;

FIGS. 5A, 5B, and 5C are perspective, top, and exploded views,respectively, of a compressor suitable for use in the apparatus of FIGS.1A and 1B;

FIG. 6A is a top cross-sectional view of the compressor taken along line6A-6A of FIG. 5A;

FIG. 6B is a side sectional view of the compressor taken along line6B-6B of FIG. 5B;

FIG. 7 is a top view of a manifold base that defines part of an airmanifold in the apparatus of FIGS. 1A and 1B;

FIGS. 8A and 8B are bottom and top views, respectively, of a manifoldcap that attaches to the manifold base of FIG. 7;

FIGS. 9A and 9B are perspective views of upper and lower sides of amanifold base that defines part of an oxygen delivery manifold in theapparatus of FIGS. 1A and 1B;

FIGS. 10A-10C are bottom, side, and top views, respectively, of a sievebed cap that defines part of the apparatus of FIGS. 1A and 1B;

FIG. 11 is a graph showing the pressure drop of air flowing though apassage as a size of the passage increases based upon exemplary averageflow rates;

FIG. 12 is a graph illustrating the relationship between the flow ratioand oxygen purity;

FIGS. 13 and 14 are graphs illustrating the power consumption versuspurity;

FIG. 15 is a graph illustrating the relationship between oxygen outputand oxygen purity levels;

FIG. 16 is a table of various performance criteria of the portableoxygen concentrator of the present invention at different flow ratesettings;

FIG. 17 is a flow chart illustrating the process for setting the ValveTime used in the process for driving the sieve beds;

FIG. 18 is a graph illustrating the relationship between the sievebed/product tank pressure and Valve Time;

FIG. 19 is a flow chart explaining the control of the motor in thecompressor used in the apparatus of the present invention;

FIG. 20 is chart illustrating the relationship between the minute volumeand the Target Pressure;

FIGS. 21-23 are a top perspective views of the portable oxygenconcentrator shown housed in a carrying bag showing various panelseither open or closed;

FIGS. 24-32 illustrate a touch screen user interface used in theapparatus of the present invention;

FIG. 33 is a table of the various alarm icons capable of being displayedon the user interface;

FIG. 34 is a chart comparing the portable oxygen concentrator of thepresent invention to existing devices;

FIG. 35 is a chart showing various parameters of the apparatus of thepresent invention at different flow settings;

FIG. 36 is a schematic illustration of an oxygen concentration systemthat includes an oxygen concentrator and an oxygen conserving devicethat is separate from the oxygen concentrator;

FIG. 37 is a schematic illustration of an oxygen concentration systemthat includes an oxygen concentrator and an oxygen conserving devicedisposed in a common chamber in a carrying bag;

FIG. 38 is a schematic illustration of an oxygen concentration systemthat includes an oxygen concentrator and an oxygen conserving devicedisposed in a carrying bag in separate chambers;

FIG. 39 is a schematic diagram of a liquefaction system using the oxygenconcentration system of the present invention;

FIG. 40 is a schematic diagram of a transfill system using the oxygenconcentration system of the present invention;

FIG. 41 is a perspective view of a compressor and sound reducingtechniques for use with the compressor;

FIG. 42 is a chart showing the discharge rate characteristic of abattery suitable for use in the present invention; and

FIG. 43 is a top, cross-sectional view of a wobble-piston compressorsuitable for use in the apparatus of the present invention;

FIGS. 44A and 44B are front and side views, respectively, of a diaphragmused in the compressor of FIGS. 5A-6C; and

FIG. 45 is a top cross-sectional view of an alternative embodiment for acompressor suitable for use in the present invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

FIGS. 1A-3 illustrate a portable oxygen concentrator apparatus 10according to the principles of the present invention. Generally,apparatus 10 includes a plurality of sieve beds or tanks 12A, 12B, acompressor 14, a lower or air manifold 16 defining a plurality ofpassages 62-68 therein, a storage tank or reservoir 18, a set of aircontrol valves 20 for creating one or more flow paths through thepassages 62-68 within the air manifold 16, and an upper or oxygendelivery manifold 102. A controller 22 is coupled to the air controlvalves 20 to selectively open and close the air control valves tocontrol airflow through the air manifold 16, and, consequently, throughthe sieve beds 12. Controller 22 is also coupled to an input/outputdevice 23 that is used, for example, to set the operating parameters,such as the oxygen flow rate, of the apparatus.

It should be noted that the air control valves are collectively referredto using reference number 20, and are individually designated as valves20 a _(e), 20 a _(s), 20 b _(e), 20 b _(s). Likewise, the sieve beds arecollectively referred to using reference numeral 12, and areindividually designated as sieve beds 12A and 12B. It should also benoted that controller 22 is shown in communication with the variouselements of apparatus 10 via dashed lines, and that only one dashed lineis shown between controller 22 and valve 20 b _(s) for ease ofillustration. In the actual device, controller 22 is in communicationwith each air control valve.

Optionally, apparatus 10 may include one or more additional components,e.g., one or more check valves, filters, sensors, electrical powersources (not shown), and/or other components, at least some of which maybe coupled to controller 22 (and/or one or more additional controllers,also not shown), as described further below. It will be appreciated thatthe terms “airflow”, “air”, or “gas” are used generically herein, eventhough the particular fluid involved may be ambient air, pressurizednitrogen, concentrated oxygen, and the like.

A. Sieve Beds

Turning now to FIG. 4, each sieve bed 12A or 12B includes an outercasing 30, e.g., in the shape of an elongate hollow cylinder, includinga first or air inlet/outlet end 32 and a second or oxygen inlet/outletend 34. Casing 30 may be formed from substantially rigid material, e.g.,plastic, such as acrylonitrile butadiene styene (“ABS”), polycarbonate,and the like, metal, such as aluminum, or composite materials. Inexemplary embodiments, casing 30 may have a diameter between about twoand ten centimeters (2-10 cm), and a length between about eight andthirty centimeters (8-30 cm). Although casing 30 is shown having a roundcylindrical shape, it will be appreciated that the casing may have otherdesired shapes, e.g., that may depend upon spatial, performance, and/orstructural criteria. For example, casing 30 may have an elliptical,square, rectangular, or other regular or irregular polygonal shapedcross-section (not shown).

Casing 30 is at least partially filled with a filtration media or sievematerial 36 to provide a sieve bed 12A, 12B capable of adsorbingnitrogen from air delivered into the sieve bed under pressure. To holdsieve material 36 within casing 30, the sieve bed includes discs orplates 38 a and 38 b adjacent each of the first and second ends 32, 34of the casing, respectively. Plates 38 a and 38 b are spaced apart fromone another to define a desired volume between the plates 3 withincasing 30. For example, the desired volume may be between about onehundred fifty and six hundred cubic centimeters (150-600 cm³), which maybe filled with sieve material 36. In an exemplary embodiment, the volumeof sieve material 36 within each sieve bed 12A, 12B is about forty fourcubic inches (44 in³), as explained further below.

Plates 38 may include one or more openings or pores (not shown)therethrough to allow airflow through the plates. For example, theplates may be formed from sintered plastic, thereby providing poreswithin the plastic material that are smaller than the grain size ofsieve material 36, thereby allowing airflow though the plates.Alternatively, plates 38 may be formed from plastic, metal, or compositematerials having multiple holes or pores formed therethrough. Forexample, the holes may be created when the plates are formed, e.g., bymolding the plates and holes simultaneously. In another alternative,plates 38 may be formed as solid panels, e.g., cut from stock, molded,etc., and the holes may be created through the panels, e.g., bydrilling, laser cutting, and the like.

Generally, sieve beds 12 are filled such that there are no substantialvoids in sieve material 36, e.g., such that the sieve material issubstantially packed between plates 38. The resulting sieve bed, whichincludes the components shown in FIG. 4 only, weighs between about0.25-1.50 pounds each.

In the embodiment shown, lower plate 38 a is substantially stationary,e.g., fixed to first end 32 of casing 30, e.g., by one or morecooperating connectors or fasteners (not shown), adhesives, sonicwelding, and the like. Upper plate 38 b is disposed adjacent second end34, yet movable within casing 30. For example, the present inventioncontemplated biasing upper plate 38 b toward lower plate 38 a, e.g., bya spring or other biasing mechanism 39, which compresses sieve material36 between plates 38. If sieve material 36 settles or somehow escapesfrom sieve bed 12A, 12B, upper plate 38 b automatically moves downwardlytowards lower plate 38 a to maintain the sieve material under a desiredcompression. This compression prevents sieve material 36 from movinginto other areas of apparatus 10 when it has become powderized fromoperation and/or may counteract flow-induced forces that may otherwisecause the sieve material to fluidize.

The porosity of plates 38 may be substantially uniform across thecross-section of a sieve bed 12, e.g., to ensure that flow into and/orout of the sieve bed is substantially evenly distributed across the areaof first and second ends 32, 34. Alternatively, the porosity of plates38 may be varied in a desired pattern or only a portion of the platesmay be porous. In yet another alternative, plates 38 may have a solidwall and may include one or more openings therethrough, e.g., in adesired pattern.

Sieve material 36 may include one or more known materials capable ofadsorbing nitrogen from pressurized ambient air, thereby allowing oxygento be bled off or otherwise evacuated from sieve beds 12. Exemplarysieve materials suitable for use herein include synthetic zeolite, LiX,and the like, such as UOP Oxysiv 5, 5A, Oxysiv MDX, Arkema N5, N51, orZeochem ZI0-06. It may be desirable to provide multiple layers of sievematerial 36 within each sieve bed 12A, 12B, e.g., providing sievematerial with different properties in layers between first end 32 andsecond end 34.

For example, because sieve material generally absorbs water, which maycause some sieve material to deteriorate, sieve material may be providedat first end 32 that is capable of absorbing water without substantiallyimpacting its durability and/or ability to adsorb nitrogen. In anexemplary embodiment, a first layer 36 a is provided adjacent first end32 having a depth, which is a dimension that is parallel to the lengthof the sieve beds, that is between about ten and thirty percent of theoverall height of sieve material, such as Oxysiv material. A secondlayer 36 b is provided that includes a high performance adsorptionmaterial, such as Oxysiv MDX. Second layer 36 b may substantially fillthe remainder of the sieve bed. Of course, one or more additional layersof sieve material may be provided (not shown) having desired properties.Thus, during use, when ambient air enters first end 32 of sieve bed 12A,12B, first layer 36 a substantially absorbs moisture in the air, suchthat second layer 36 b is exposed to relatively dry air, therebysubstantially reducing the risk of damaging the sieve material of secondlayer 36 b. It has been determined for Oxysiv MDX that between about0.5-1.5 pounds, and preferably about one pound, of the sieve materialper liter per minute (lpm) outlet production provides efficientadsorption.

Although two sieve beds 12A and 12B are shown in the figures, it will beappreciated that one or more sieve beds may be provided, e.g., dependingupon the desired weight, performance efficiency, and the like.Additional information on sieve beds and/or sieve materials that may beincluded in apparatus 10 may be found in U.S. Pat. No. 4,859,217, theentire disclosure of which is expressly incorporated by referenceherein.

B. Gas Storage Reservoir and Sieve Assembly

Returning to FIGS. 1A, 1B, and 2, reservoir 18 is an elongate tubularcasing 70 having a lower or first end 94, which may be substantiallyenclosed or open, and an upper or second end 96, which may also besubstantially enclosed or open (e.g., if capped by a manifold or othercomponent, as described elsewhere herein). As shown, casing 70 has anirregular hourglass shape allowing reservoir 18 to be nested betweenand/or adjacent to sieve beds 12A and 12B. This minimizes the spaceoccupied by reservoir 18 to help reduce the overall size of apparatus10. In the illustrated exemplary embodiment, casing 70 has a curvedouter wall 71 that extends between sieve beds 12A, 12B to provide ordefine a finished outer surface for the apparatus 10, as best seen inFIGS. 1A and 1B. Casing 70 is formed from any suitable material.Examples of such materials include plastic, such as ABS, polycarbonate,and the like, metal, such as aluminum, or composite materials, similarto the other components of apparatus 10 described herein.

As shown in FIGS. 2 and 10A-10C, the present invention contemplatesproviding a cap 80 to at least partially close upper end 96 of casing70. Cap 80 may be substantially permanently or removably attached tosecond ends 34 of sieve beds 12A, 12B and/or upper end 96 of reservoir18, e.g., using one or more connectors, fasteners, adhesives, sonicwelding, and the like. Cap 80 includes one or more openings 82, 84therein for allowing oxygen to flow into and out of sieve beds 12A, 12Band/or reservoir 18, as explained further below.

Turning to FIG. 10A, cap 80 includes a purge orifice 81 (shown inphantom) to provide a passage communicating directly between secondsends 34 of sieve beds 12A and 12B. Purge orifice 81 remains continuouslyopen, thereby providing a passage for oxygen to pass from one sieve bedto the other, e.g., while the one sieve bed is charging and the other ispurging, as described further below. In an exemplary embodiment, purgeorifice 81 has a precisely determined cross-sectional size, e.g.,between about 0.015-0.35 inch, or about 0.020 inch diameter, that isdetermined based upon one or more flow or other performance criteria ofthe sieve beds 12A, 12B, as explained further below. For example, purgeorifice 81 is sized such that between about two and a half and tenliters per minute (1.5-10 1pm) of oxygen, e.g., about five liters perminute (5 1pm), flows through purge orifice 81 in either direction at apressure differential of about five pounds per square inch (5 psi)across the purge orifice.

The present invention also contemplates providing a purge valve (notshown) in purge orifice 81 to control the flow of gas between the sievebeds. Such a purge valve has the effect of varying the purge orificeflow as the beds are alternately charged and purged.

Alternatively, the purge orifice may extend between sieve beds 12A and12B via reservoir 18. For example, the purge orifice may include a firstpassage (not shown) extending along cap 80 that communicates betweensieve bed 12A and reservoir 18, and a second passage (also not shown)extending along cap 80 that communicates between sieve bed 12B andreservoir 18.

Optionally, if lower end 94 of casing 70 is open, a cap (not shown) mayalso be provided for substantially closing the lower end of the casing.Such a cap, if provided, may be substantially permanently or removablyattached to the lower end of the casing. Alternatively, the presentinvention contemplates enclosing lower end 94 of casing 70 by a portionof air manifold 16, e.g., when reservoir 18 is mounted onto or adjacentair manifold 16, as describe further below.

In a further alternative, apparatus 10 may include multiple reservoirs(not shown) that may be provided at one or more locations with theapparatus, e.g., placed in different locations where space if available,yet minimizing the overall size of the apparatus. The present inventioncontemplates that the reservoirs are connected to one another via one ormore flexible tubes (not shown) and/or via oxygen delivery manifold 102to allow oxygen to be delivered to and withdrawn from the reservoirs.Optionally, in this alternative, one or more valves may be provided forcontrolling flow of oxygen into and out of the reservoirs.

In addition or alternatively, apparatus 10 may include one or moreflexible reservoirs, e.g., bags or other containers that may expand orcontract as oxygen is delivered into or out of them. The reservoirs mayhave predetermined shapes as they expand or more expand elastically tofill available space within apparatus 10. Optionally, one or more rigidreservoirs may be provided that communicate with one or more flexiblereservoirs (not shown), e.g., to conserve space within the apparatus. Infurther alternatives, one or more reservoirs may be provided as portionsof one or both of air manifold 16 and oxygen delivery manifold 102,rather than as a separate component.

C. Gas Compressor

Returning to FIGS. 1A, 1B, and 2, with additional reference to FIGS. 5A,5B, and 6, an exemplary embodiment of compressor 14 suitable for use inthe present invention will now be described. It is to be understood thatcompressor 14 can any device capable of drawing ambient air intoapparatus 10 and compressing the air to one or more desired pressuresfor delivery to the sieve beds. Suitable compressors include, but arenot limited to, articulated piston (wrist pin connecting rod to piston),diaphragm, wobble piston (piston fixed to connecting rod), scroll,linear, and rotary vane compressors. An example of a wobble pistoncompressor 400 suitable for use in the present invention is shown inFIG. 43.

In the embodiment shown in FIGS. 5A-6B, compressor 14 is a multipleheaded device that includes a motor 40, a cam assembly 42 coupled to themotor, drive shafts or rods 44 coupled to the cam assembly, and aplurality of diaphragm assemblies or heads 46 coupled to the driveshafts. Motor 40 may be a brushless DC motor, such as the Pittman 4413,which has a relatively low weight and long operational life. Rods 44 areindividually referred to using reference numerals 44 a, 44 b, and 44 cand are collectively referred to using reference numeral 44. Similarly,heads 46 are individually referred to using reference numerals 46 a, 46b, and 46 c and are collectively referred to using reference numeral 46.

Motor 40 includes an output shaft 41 defining a central axis 43. Motor40 may include a base plate, frame, or other support 45 extending fromhousing 47. As explained further below, support 45 may be used to securediaphragm assemblies 46 directly to motor 40, which may reduce vibrationof the diaphragm assemblies. This construction may also facilitateinstallation of the compressor 14 into a concentrator or other device,e.g., by allowing motor 40 and heads 46 to be preassembled and theninstalled as a single component.

As best seen in FIG. 5C, output shaft 41 is coupled to cam assembly 42such that rotation of the output shaft 41 causes a crankshaft 49 torotate about central axis 43. As shown in FIGS. 5B and 6B, crankshaft 49may be an elongate cylindrical barrel including a bore 51 in one end forreceiving output shaft 41 therein. Crankshaft 49 may be secured tooutput shaft 41, e.g., by a mating lock and key arrangement, aninterference fit, a set screw (not shown), and the like. Bore 51 may beoffset from the central axis 43, such that crankshaft 49 rotateseccentrically about the central axis when output shaft 41 is rotated bymotor 40. It will be appreciated that other arrangements may be providedfor securing crankshaft 49 to output shaft 41.

As best seen in FIGS. 5A-6B, each diaphragm assembly 46 includes ahousing 48, a diaphragm 50 secured to the housing to define a chamber52, and a set of check valves 54 for allowing air to be drawn into andforced out of the chamber. Housing 48 may include one or moresubstantially rigid parts providing a support structure for diaphragm 50and at least partially defining chamber 52. Housing 48 may be formedfrom plastic, such as ABS or polycarbonate, metal, or compositematerials, e.g., made by molding, casting, machining, and the like.

Each of the diaphragm assembly 46 generally includes a cover 53including inlet and outlet ports 59, a head 55 including inlet andoutlet valves 254, and a retainer 57 for mounting diaphragm 50 to head55. Diaphragm 50, head 55, and retainer 57 generally define a chamber 52into which ambient air may be drawn and from which compressed air may bedelivered on a cyclical basis, as explained elsewhere herein. Withadditional reference to FIGS. 44A and 44B, an outer lip or otherperimeter 61 of diaphragm 50 may be secured between head 55 and retainer57, while allowing a central portion 63 to move.

Diaphragm 50 is substantially permanently or removably attached tohousing 48, e.g., using an interference fit, one or more connectors,fasteners adhesives, and the like (not shown), that may provide asubstantially airtight seal between the diaphragm and the housing.Diaphragm 50 may be formed from flexible or semi-rigid material that mayrepeatedly deflected a desired distance during operation of thecompressor 14, e.g., Ethylene Propylene Diene Monomer (“EPDM”) or “BUNA”rubber (synthetic rubber made by polymerizing butadiene), and the like,VITON, or liquid silicone rubber (“LSR”) materials having sufficientflexibility, resiliency, and/or other appropriate properties. Diaphragm50 may include supports 65 for coupling diaphragm 50 to an associatedrod 44.

In exemplary embodiments, housing 48 and diaphragm 50 may have square orrectangular cross-sections (extending into the page of FIG. 6), e.g.,between about one and three inches (1-3 in) on a side. Housing 48 mayhave a depth between about 0.25-1.5 inches, thereby providing chamber 52defining a volume. In an exemplary embodiment, diaphragm assemblies 46have a square cross-section with each of the height and width beingabout two inches (50 mm). It will be appreciated, however, that housing48 and diaphragm 50 may have other cross-sectional shapes, e.g.,circular, elliptical, and the like.

As best seen in FIGS. 44A and 44B, diaphragm 50 may include a thickerperipheral portion 69 between outer lip 61 and central portion 63, whichmay enhance rigidity, and consequently efficiency, of the diaphragmassemblies. For example, the increased rigidity may limit motion ofperipheral portion 69 when central portion 63 of diaphragm 50 isdirected inwardly and outwardly by rod 44, as explained elsewhereherein. Alternatively, as shown in phantom at the lower portion of FIG.44B and indicated by reference numeral 69′, peripheral portion 69′ mayinclude a thickness similar or even less than central portion 63. Asshown, peripheral portion 69′ may also be curved or otherwise contoured,for example, to control the deflection of the diaphragm.

Diaphragm 50 is coupled to drive shaft 44 such that diaphragm 50 maymove inwardly and outwardly relative to chamber 54 as the drive shaftreciprocates along its longitudinal axis away from and towards camassembly 42. Thus, the volume of chamber 54 may be increased anddecreased as diaphragm 50 moves away from and towards the chamber todraw air into and force air out of the chamber, respectively.

Optionally, as shown in FIG. 6A, housing 48 may include one morepartitions defining passages, e.g., an inlet passage 56 _(in) and anoutlet passage 56 _(out). As explained further below, inlet and outletpassages 56 _(in), 56 _(out) communicate with respective passages 62, 64in air manifold 16, e.g., via ports 57 (not shown in FIG. 6A, see, e.g.,FIG. 2) on the bottom of housing 48. An inlet check valve 54 _(in) isprovided in line with inlet passage 56 _(in), e.g., in the partitionbetween chamber 52 and inlet passage 56 _(in). Inlet check valve 54_(in) opens when exposed to a negative pressure within chamber 52, i.e.,as diaphragm 50 is directed away from chamber 52, and closes whenexposed to a positive pressure within the chamber, i.e., as diaphragm 50is directed towards chamber 52. Similarly, an outlet check valve 540_(out) is provided in line with outlet passage 56 _(out) that opens whenexposed to a positive pressure within chamber 52 and closes when exposedto a negative pressure within the chamber. Check valves 54 may simply bespring biased valves that open in one direction depending upon thepressure differential across the valve, such as conventionalumbrella-type valves.

As shown in FIGS. 5C-6B, rods 44 may between respective diaphragms 50and the crankshaft 49. Rods 44 include first ends including hubs 71 andsecond ends including rings 73. Hubs 71 may be received in or otherwisesecured to supports 65 of diaphragms 50, and rings 73 may be disposedaround crankshaft 49. A bearing 77 may be provided between each ring andthe crankshaft 242. Thus, crankshaft 49 may rotate freely within thebearings, causing the rings, and consequently, rods 44 may be axiallydisplaced towards and away from central axis 43. This action causesdiaphragms 50 to move away from and into chambers 52 to compress airdrawn into the chambers.

More specifically, during operation, motor 40 may be continuously orselectively activated to rotate a cam 43 of cam assembly 42 and therebycause drive shafts 44 to reciprocate axially away from and towards camassembly 42. For example, cam assembly 42 may be configured such thatdrive shaft 44 has a total axial displacement of between about three andthirteen millimeters (3-13 mm). This reciprocation causes diaphragms 50to move in and out relative to housings 46, thereby drawing ambient airinto chambers 52 via inlet passages 56 _(in) and forcing compressed airout of the chambers via outlet passages 56 _(out). The displacement ofthe center of diaphragm 50 may correspond one-to-one with thedisplacement of drive shaft 44. Drive shafts 44 may change the volume ofchamber 52, e.g., by between about eighty and ninety five percent(80-95%) above and below its relaxed volume (when diaphragm 50 issubstantially relaxed or not subjected to any forces).

In an exemplary embodiment, the reciprocal movement of drive shafts 44is staggered or offset in time for each of diaphragm assemblies 46 a-46c in a predetermined pattern, e.g., based upon the configuration of cam43 or cam assembly 42. Thus, compressed air is generated sequentially byeach head 46. This is believed to minimize the amount of vibration ornoise generated by compressor 14, e.g., such that vibration or movementof one of the diaphragm assemblies at least partially offsets theothers.

In addition, because the diaphragm assemblies may be angularly offsetfrom one another, e.g., by one hundred twenty degrees (120°) whendisposed symmetrically about cam assembly 42, this may also offset orminimize vibrations created during operation of compressor 14. Bycomparison, in an alternative embodiment, two diaphragm assemblies (notshown) may be provided on opposite sides of the cam assembly in a linearconfiguration defining an axis, although this configuration may increasevibrations along the axis. As the number of heads is increased, thedynamic peak-to-peak pressure oscillations are reduced, which provides abenefit in reduced sound and reduced vibrations due to reduced pressurepulsations.

Alternatively, more than three (3) heads may be provided, although thismay increase the cost and/or complexity of operation of apparatus 10. Inorder to minimize vibration, it may be desirable to provide an oddnumber of diaphragm assemblies (e.g., thee, five, seven, etc.), e.g., ina symmetrical spoke configuration that does not create a linear axisbetween any of the diaphragm assemblies, which may at least partiallyoffset vibrations between the various heads.

As best seen in FIGS. 5C and 6B, rods 44 may be stacked axially on thecrankshaft 49, while diaphragm assemblies 46 are coplanar within oneanother. In order to accommodate this arrangement, at least some of therods may include an offset between the rings and the hubs. For example,a central rod may extend substantially perpendicularly to central axis43 within a plane, a lower rod may include an offset such that the lowerrod is coupled to crankshaft 49 below the plane, and an upper rod mayinclude an offset such that the upper rod is coupled to the crankshaft49 above the plane. In this configuration, each of the hubs may then bedisposed within the plane, allowing the hubs to be connected torespective diaphragms 50.

One of the advantages of this arrangement is that it may minimize afootprint of the diaphragm assemblies, and consequently of the entirecompressor. For example, the heads 46 may be mounted directly to support45 on motor 40. Support 45 may extend outwardly from the motor toprovide a lip or other structure to which an upper edge of the heads 46may be mounted, e.g., using fasteners, such as bolts screws, rivets, andthe like, adhesives or other bonding, detents or other matingconnectors, and the like. With heads 46 mounted directly to motor 40,the heads may be located relatively close to central axis 43.

Wobble piston compressor 400 shown in FIG. 43 is similar in manyrespects to the diaphragm compressor shown in FIGS. 5A-6B except thatdiaphragm 50 is replaced with a piston 402. Each piston includes apiston cup seal 404 to maintain a gas-tight seal between chamber 52 andthe opposite side of piston 402.

An alternative configuration of a compressor suitable for use in theportable oxygen concentration of the present invention is shown in FIG.45. In this alternative, a motor (not shown) includes an output shaftdefining a central axis 341, similar to motor 40. A crankshaft 342 iseccentrically coupled to the output shaft, and a rotor 345 is disposedaround the crankshaft (e.g., within one or more bearings, not shown,between rotor 345 and crankshaft 342). A plurality of heads 346, such asany of those disclosed herein, may be disposed around central axis 341,and rods 344 may extend from heads 346 to rotor 345. Thus, as crankshaft342 rotates about central axis 341, rotor 345 may wobble around thecentral axis, thereby causing rods 344 to move towards and away fromcentral axis 341 to compress air within heads 346, similar to theprevious embodiments.

The configuration shown in FIG. 45, however, may have a larger footprintthan the configuration of FIGS. 5A-6B, because of the space required forrotor 345. Thus, this configuration may require more space on a mountingsurface, such as an air manifold of an oxygen concentrator. However,this configuration may allow the motor to be supported lower between theheads, which may reduce a height of the compressor, which may bebeneficial in some applications.

In the embodiment shown in FIGS. 5A-6B, as well as that in FIG. 45, thereciprocal movement of the rods may be staggered or offset in time foreach of the heads. With three heads distributed substantially evenlyabout the central axis, the heads may be out of phase by about onehundred twenty degrees (120°). Thus, compressed air may be generatedsequentially by each of the heads. In addition, because the heads areangularly offset from one another, this configuration may offset orminimize vibrations created during operation of the compressor, asdescribed elsewhere herein.

D. Air and Oxygen Manifolds

Turning to FIGS. 1B, 2, and 7-8B, lower or air manifold 16 generallyincludes one or more substantially planar structures defining aplurality of passages 62-68 therein. Generally, air manifold 16 issealed such that passages 62-68 are substantially airtight other than atopenings 72-79, 86-90. Openings 72-79, 86-90 may allow other components,e.g., compressor 14, sieve beds 18, and control valves 20, tocommunicate with passages 62-68 for moving air through air manifold 16in a desired manner, as explained further below. Optionally, airmanifold 16 may include one or more holes, pockets, and the like forreceiving mounts, connectors, and/or fasteners (not shown), e.g., forattaching components of apparatus 10 to air manifold 16, e.g., sievebeds 12A, 12B, compressor 14, reservoir 18, and/or air control valves20.

In an exemplary embodiment, air manifold 16 is substantially rigid,e.g., thereby providing or enhancing a structural integrity of apparatus10. In one embodiment, air manifold 16 defines one or more outerstructural surfaces for apparatus 10, e.g., a lower or bottom surface ofthe apparatus, thereby eliminating the need for an additional lowerexterior skin. Air manifold 16 may be formed from any engineering gradematerial, e.g., plastic, such as ABS, polycarbonate, and the like;metal, such as aluminum, and the like; or composite materials. Airmanifold 16 may be formed by injection molding, casting, machining, andthe like.

In an exemplary embodiment, air manifold 16 is formed from relativelylightweight plastic material, e.g., such that the air manifold weighsnot more than about 0.25-4.0 pounds. Alternatively, all or one or moreportions of air manifold 16 may be formed from resilient semi-rigid orflexible material, e.g., to increase the durability and/or shockresistance of apparatus 10.

In the embodiment shown, air manifold 16 includes (a) a manifold base 58including a plurality of channels therein that at least partially definepassages 62-68, and (b) a manifold cap 60 that mates with manifold base58 to substantially enclose the channels to further define the passages.It will be appreciated that air manifold 16 may be formed from one ormore components, instead of the manifold base and the manifold cap, thatmate together or otherwise cooperate to define passages 62-68 describedherein.

As best seen in FIG. 7, manifold base 58 includes channels that at leastpartially define one or more compressor inlet passages 62, compressoroutlet passages 64, sieve bed passages 66 a, 66 b, and exhaust passages68. Portions of manifold base 58 unnecessary to define passages 62-68and/or mounting surfaces may be omitted, e.g., to reduce the overallweight of the manifold without substantially impacting its structuralintegrity. Alternatively, manifold base 58 may have a substantiallycontinuous lower wall, e.g., which may be substantially smooth and/ormay include legs or other components (not shown) upon which apparatus 10may be set.

In addition or alternatively, manifold base 58 may include at least aportion of a side wall 59, e.g., which may define another outerstructural surface of apparatus 10. In a further alternative, as shownin FIG. 2, side wall 159 may be part of manifold cap 60, rather thanmanifold base 58. In yet another alternative, air manifold 16 may berelatively flat (rather than “L” shaped), and the side wall (59, 159)may be a separate component (not shown) that may be connected orotherwise attached to air manifold 16 or oxygen manifold 102.

Turning to FIGS. 8A and 8B, manifold cap 60 includes one or morechannels that mate with the channels in manifold base 58 to furtherdefine passages 62-68, e.g., compressor inlet passages 62, compressoroutlet passages 64, sieve bed passages 66, and exhaust passages 68.Alternatively, the channels in manifold cap 60 may be slightly larger orsmaller than the channels in manifold base 58 such that the channelwalls overlap, which may enhance the connection between manifold cap 60and manifold base 58. In another alternative, manifold cap 60 has asubstantially smooth lower surface that mates against the channel wallsand/or other components of manifold base 58 to further define passages62-68.

Manifold cap 60 may be attached to manifold base 58 using one or moreconnectors, e.g., cooperating detents, such as tabs and correspondinggrooves, or fasteners, such as screws, rivets, bolts, and the like. Inaddition or alternatively, manifold cap 60 may be attached to manifoldbase 58 using adhesives, sonic welding, and the like, e.g., along one ormore contact surfaces between the manifold base and the manifold cap.

With continued reference to FIGS. 8A and 8B, manifold cap 60 includes aplurality of openings 72-79, 86-90 that communicate with passages 62-68.For example, manifold cap 60 includes an air inlet port 79 thatcommunicates with compressor inlet passage 62. Inlet port 79 is coupledto a tube or other hollow structure (not shown) extending to an inletopening 160 a, 160 b (not shown in FIG. 8A or 8B, see FIG. 2) in anouter surface of apparatus 10, e.g., to allow ambient air to be drawninto the apparatus. Optionally, as shown in FIG. 3, an inlet air filter162 may be provided in line before inlet port 79 to remove dust or otherparticles from the ambient air drawn into inlet opening 160 a, 160 bbefore it enters compressor 14.

Manifold cap 60 includes multiple pairs of openings 72, 74 forcommunicating with compressor 14. In the embodiment shown, manifold cap60 includes thee pairs of openings 72, 74 corresponding to ports 57 (notshown, see FIG. 2) on the three diaphragm assemblies 46 of compressor14. Each pair of openings 72, 74 is spaced apart a predetermineddistance similar to the spacing of ports 57 on diaphragm assemblies 46.One or both of openings 72, 74 and ports 57 may include nipples or otherextensions to facilitate a substantially airtight connection betweendiaphragm assemblies 46 and manifold cap 60. Ports 57 are connected toopenings 72, 74, e.g., by one or more of interference fit, matingthreads, cooperating detents, adhesives, and the like.

When compressor 14 is mounted to or adjacent air manifold 16, inletpassages 56 _(in) of diaphragm assemblies 46 communicate with openings72, and consequently with compressor inlet passage 62. During use, wheneach diaphragm assembly 46, in turn, draws in outside air via inletpassages 56 _(in), air may be drawn through respective openings 72,compressor inlet passage 62, and inlet port 79. Similarly, outletpassages 56 _(out) of diaphragm assemblies 46 communicate with openings74, and consequently with compressor outlet passage 64. During use, wheneach of diaphragm assemblies 46 delivers compressed air out outletpassages 56 _(out), the compressed air enters the respective openings 74into compressor outlet passages 64 in air manifold 16.

With continued reference to FIGS. 8A and 8B, manifold cap 60 alsoincludes a plurality of air control valve openings 86, 88 adjacent oneanother that overly compressor outlet passage 64, sieve bed passages 66,and/or exhaust passage 68. Thus, when manifold cap 60 is attached tomanifold base 58, air control valve openings 86, 88 communicate withrespective passages 64-68. In particular, supply valve inlet openings 86_(in) communicate with compressor outlet passage 64, while exhaust valveinlet openings 88 _(in) communicate with respective sieve bed passages68. Supply valve outlet openings 86 _(out) communicate with respectivesieve bed passages 66, while exhaust valve outlet openings 88 _(out)communicate with exhaust passage 68.

Manifold cap 60 includes sieve bed openings 90 a and 90 b thatcommunicate with enlarged portions of sieve bed passages 66. Thus, sievebed openings 90 a, 90 b communicate with first ends 32 of respectivesieve beds 12 when the sieve beds are mounted to or adjacent airmanifold 16. Further, as best seen in FIG. 8B, manifold cap 60 alsoincludes one or more exhaust openings 92 that communicates with exhaustpassage 68.

Optionally, a tube, nozzle, or other device (not shown) may be coupledto exhaust opening(s) 92 to direct exhaust air (generally concentratednitrogen) from sieve beds 12, as explained further below. In oneembodiment, the exhaust gas is directed toward controller 22 or otherelectronics within apparatus 10, e.g., for cooling the electronics.Using air with increased nitrogen content as a cooling fluid for theinternal electronics provides a safety feature for apparatus 10, namelyreducing the risk of fire if the electronics ever overheat or short.Since some of the oxygen has been removed from the exhaust air, theexhaust air is less likely to support a fire. Further, with the exhaustair being directed into the interior of apparatus 10, if reservoir 18 orsieve beds 12 were ever to develop a leak communicating with theinterior of apparatus 10, the resulting gas mixture would have no moreoxygen (as a percentage of volume) than ambient air.

As described further below, air control valves 20 may be mounted tomanifold cap 60 over valve openings 86, 88. The air control valves areselectively opened and closed to provide flow paths, e.g., fromcompressor outlet passage 64 to sieve bed passages 66 and/or from sievebed passages 66 to exhaust passage 68. For example, with additionalreference to FIG. 3, when supply air control valve 20 a _(s) is open, aflow path is defined from compressor 14 through openings 72, compressorpassage 62, supply inlet openings 86 _(in), air control valve 20 a _(s),supply outlet opening 86 _(out) and sieve bed passage 66 a, into sievebed 12A. When exhaust air control valve 20 b _(E) is open, a flow pathis defined from the sieve bed 12B, though sieve bed passage 66 b,exhaust inlet openings 88 _(in), air control valve 20 b _(E), exhaustoutlet openings 88 _(out) exhaust passage 68, and out exhaust opening(s)92.

Air manifold 16 replaces the need for a plurality of tubes and valvesthat would otherwise be necessary to deliver air to and from sieve beds12. Because these individual tubes and valves are eliminated andreplaced with a simple manifold including not more than four air controlvalves 20, air manifold 16 reduces the overall size, weight, and/or costof apparatus 10, which may be useful, particularly in order to makeapparatus 10 convenient, easy to use, and/or inexpensive.

Alternatively, the same objective may be achieved if two 3-way valves,or one 4-way valve was employed in a like manner.

In addition, air manifold 16 may facilitate modifications, e.g., toreduce pressure losses and/or dampen noise. For example, to minimizeenergy needs for apparatus 10, the size and/or shape of passages 62-68may be designed to reduce losses as compressed air pass through thesepassages. It has been found that if the pressure loss increases by onepound per square inch (1 psi), it may increase power consumption of theapparatus 10 by as much as ten percent (10%) or more. FIG. 11 showspressure losses that may be encountered during three exemplary averageflow rates, i.e., twenty four (24), thirty (30) and fifty (50) litersper minute (lpm). As the average flow diameter of passages 62-68 isincreased, the pressure drop is reduced significantly. Thus, it may bedesirable for passages 62-68 to have a size of at least about 0.25 inchdiameter or other equivalent cross-section.

In addition, air manifold 16 may facilitate providing baffles or othersound dampening devices or materials within the flow paths of the airmoving through apparatus 10. For example, one or more baffles, venturis,flow modifiers, and the like (not shown) may be molded directly into thechannels of manifold base 58 to absorb sound waves or reduce noisegenerated by airflow. Alternatively, such components may be inserted ormounted within the channels before manifold cap 60 is attached tomanifold base 58. In yet another alternative, air manifold 16 may allowflow control valves to be mounted directly in one or more of passages62-68.

Returning to FIGS. 1A-3, air control valves 20 may be mounted orotherwise attached to air manifold 16, e.g., to manifold cap 60. In theembodiment shown, four “two way” air control valves 20 are mounted tomanifold cap 60, e.g., using one or more connectors, fasteners,adhesives, and the like. As explained further below, four air controlvalves 20 allow each sieve bed 12A, 12B to be pressurized and/orexhausted independently of the other, optionally with the ability tooverlap the pressurization cycles.

An exemplary two-way valve that may be used for each of valves 20 is theSMC DXT valve, available from SMC Corporation of America, ofIndianapolis, Ind. This valve is a relatively small plastic pilotoperated diaphragm valve. Because of the large diaphragm area, it has avery low minimum operating pressure, which may be particularly usefulgiven the operating pressures of the apparatus 10 during use. The valvemay be provided as “normally open.” When pressure is applied to the topside of the diaphragm through the pilot valve, the diaphragm may beforced down onto a seat, shutting off the flow. Either a normally openor normally closed pilot solenoid valve may be used. Since the diaphragmvalve itself is normally open, using a normally open solenoid valve maycreate normally closed overall operation, requiring application ofelectrical energy to open the valve.

Alternatively, air control valves 20 may be replaced with two “thee-way”valves, which may require some minor changes to the openings and/orpassages in air manifold 16. Such valves, however, may be moreexpensive, complicated to operate, and/or may require greater pressureto pilot than the pressures encountered during use of apparatus 10. Infurther alternatives, one or more other multiple position valves may beprovided, instead of the four two way valves.

Returning to FIG. 2, the four air control valves illustrated therein maybe provided on a single valve manifold 21, e.g., an aluminum manifold,and the ports may be threaded inlet and outlet ports provided separatelyor as part of valve manifold. After assembling air control valves 20 tovalve manifold 21, the valve manifold is mounted to air manifold 16 overopenings 86, 88. Alternatively, the individual air control valves may bemounted directly to air manifold 16, e.g., to avoid the need for valvemanifold 21 or any other fittings and/or tubing, which may furtherreduce the overall size and/or weight of apparatus 10.

Returning to FIGS. 1A, 1B, and 2, with additional reference to FIGS.9A-9B, upper or oxygen delivery manifold 102 is provided for deliveringoxygen stored in reservoir 18 to a user of apparatus 10. Similar to airmanifold 16, oxygen delivery manifold 102 provides sufficient structuralintegrity to provide an outer structural surface of apparatus 10, e.g.,thereby eliminating the need for a separate outer or upper skin for theapparatus. Oxygen delivery manifold 102 may be manufactured andassembled using similar materials and/or methods to air manifold 16,described above.

Optionally, as shown in FIG. 9B, oxygen delivery manifold 102 includesone or more ribs or other reinforcing structures 103, e.g., on a lowersurface of the oxygen delivery manifold. The reinforcing structures maybe molded or otherwise formed directly in oxygen delivery manifold 102in a desired pattern or attached to the oxygen delivery manifold, e.g.,overlying the sieve beds 12. Such reinforcing structures may reinforceoxygen delivery manifold 102, e.g., from biasing mechanism 39 within thesieve beds 12A, 12B and/or against the pressure of the air within thesieve beds, which may apply an upward force against oxygen supplymanifold 102.

In the embodiment shown in FIG. 2, oxygen delivery manifold 102 includesa manifold base 104 at least partially defining one or more oxygendelivery passages 108, 109, and a manifold cap 106 further definingoxygen delivery passages 108, 109. Oxygen delivery passages 108, 109 aredisposed adjacent one another in the manifold base 104 and include aplurality of openings 126-138 for communicating with other componentsrelated to delivering oxygen to a user of apparatus 10, as explainedfurther below. Manifold base 104 may also include one or more batteryopenings 140 a and 140 b and/or an interface window 142, which may bemolded or otherwise formed therein. Interface window 142 allows accessto user interface 144, which is necessary, for example, if the userinterface is a touch screen display 230.

Optionally, as shown in FIG. 2, manifold base 104 of oxygen deliverymanifold 102 may include at least a portion of side panel 159. Sidepanel 159 may abut, interlock, or otherwise mate with side panel 59 onair manifold 16. Side panels 59 and 159 provide an outer structural wallfor apparatus 10 that is substantially rigid. Thus, side panels 59 and159, manifolds 16 and 102, sieve beds 12A and 12B, and/or reservoir 18combined provide the necessary structural frame to support apparatus 10and its internal components. Alternatively, one or both of side panels59, 159 may be provided as a separate panel (not shown) that isconnected or otherwise attached to air manifold 16 and/or oxygendelivery manifold 102.

Returning to FIG. 2, side panel 159 may include one or more inletopenings 160 a, 160 b that communicate with an interior of apparatus 10.As shown, side panel 159 includes two inlet openings or screens 160 aand 160 b adjacent one another. Inlet openings 160 a, 160 b are providedin any desired array, e.g., in a rectangular, square, round, or otherconfiguration. In an exemplary embodiment, each of inlet openings 160 aand 160 b have a height and/or width of between about one and two inches(25-50 mm). Inlet openings 160 a and 160 b include relatively smallholes, e.g., between about 0.025-0.15 inch (0.6-4 mm) diameter, allowingair to pass easily through the inlet openings, yet preventing largeobjects from passing therethrough.

For example, first inlet opening 160 a may provide an inlet for drawingair into compressor 14, e.g., via a tubing and the like (not shown)communicating with air inlet port 79 of air manifold 16, as describedabove. Second inlet opening 160 b may provide a ventilation inlet forambient air to be drawn into the interior of apparatus 10, e.g., toassist cooling the internal electronics and/or the sieve beds. An intakefan 164 may be mounted adjacent second inlet opening 160 b, e.g., todraw ambient air into the interior of apparatus 10 at a constant orvariable speed and/or volume.

Optionally, apparatus10 may include one or more gaps, e.g., verticalspaces between sieve beds 12A, 12B and/or reservoir 18 (not shown) toallow air to escape from the interior of the apparatus. For example, itmay be desirable to have air within the interior of apparatus 10(particularly, the exhaust gas from the exhaust opening(s) 92) escapethe apparatus on the opposite end from inlet openings 160 a, 160 b toavoid drawing nitrogen-rich air back into sieve beds 12A, 12B, whichwould reduce the efficiency, and possibly effectiveness, of theapparatus. Alternatively, one or more outlet openings (not shown) may beprovided on the apparatus, e.g., in air manifold 16, oxygen deliverymanifold 102, and/or one or more side panels (not shown) to allow air toescape from within the interior of apparatus 10 in a desired manner.

E. Oxygen Delivery Components

Returning to FIGS. 2 and 3, apparatus 10 includes one or more componentsrelated to delivering oxygen from reservoir 18 to a user. Thesecomponents are attached or otherwise mounted to or adjacent oxygendelivery manifold 102, e.g., using methods similar to the methods forattaching other components of apparatus 10 described herein.

For example, a pair of check valves 110 a, 110 b may be provided inmanifold base 104 that overlie openings 82 in cap 80. Check valves 110 aand 110 b may simply be pressure-activated valves, similar to checkvalves 54 described above. When oxygen delivery manifold 102 is mountedto or adjacent sieve beds 12A, 12B and reservoir 18, check valves 110 a,110 b provide one-way flow paths from sieve beds 12A, 12B into oxygendelivery passage 108. Oxygen delivery passage 108 communicates directlyand continuously with reservoir 18 via opening 112.

A pressure sensor 114 may be provided within reservoir 18 orcommunicating with oxygen delivery passage 108. Pressure sensor 114 maydetect an absolute pressure within reservoir 18, and, consequently,within the oxygen delivery passage 108. In addition, because of thepresence of check valves 110 a and 110 b, pressure sensor 114 provides areading of the maximum pressure within sieve beds 12. Specifically,because check valves 110 and 110 b allow one-way flow of oxygen from thesieve beds into reservoir 18 and oxygen delivery passage 108, wheneverthe pressure in either sieve bed exceeds the pressure in reservoir 18,the respective check valve 110 a or 110 b is open. Once the pressurewithin either sieve bed becomes equal to or less than the pressure inreservoir 18, the respective check valve closes.

The present invention also contemplates providing an oxygen deliveryvalve 116, oxygen sensor 118, one or more pressure sensors 120, 122, andone or more air filters 124 may be provided in line with oxygen deliverypassages 108, 109, e.g., mounted to oxygen delivery manifold 102. Forexample, with additional reference to FIGS. 9A and 9B, manifold base 104may include oxygen control valve openings 126, pressure sensor openings128, 138, oxygen sensor openings 130, 132, and outlet openings 134, 136for communicating with these components. Oxygen delivery valve 116 maybe mounted to oxygen delivery manifold 102, e.g., below oxygen controlvalve openings 126, for controlling the flow of oxygen between oxygendelivery passages 108 and 109, and consequently from reservoir 18 out ofapparatus 10 to a user. The oxygen delivery valve may be a solenoidvalve coupled to controller 22 that may be selectively opened andclosed. An exemplary valve that may be used for oxygen delivery valve116 is the Hargraves Technology Model 45M, which has a relatively largeorifice size, thereby maximizing the possible flow though the oxygendelivery valve. Alternatively, it may also be possible to use a ParkerPneutronics V Squared or Series 11 valve.

When oxygen delivery valve 116 is open, oxygen flows from oxygendelivery passage 108, through oxygen control valve openings 126 a, 126b, oxygen delivery valve 116, oxygen control valve opening 126 c, andinto oxygen delivery passage 109. Oxygen delivery valve 116 may beopened for desired durations at desired frequencies, which may be variedby controller 22, thereby providing pulse delivery as explained furtherbelow. Alternatively, controller 22 may maintain the oxygen deliveryvalve 116 open to provide continuous delivery, rather than pulseddelivery. In this alternative, controller 22 may throttle oxygendelivery valve 116 to adjust the volumetric flow rate to the user.

In the illustrated embodiment, pressure sensor 120 is mounted to and/orbelow oxygen delivery manifold 102 such that ports of the pressuresensor are coupled to or otherwise communicate with pressure sensoropenings 128. Thus, the ports of pressure sensor 120 measure a pressuredifference between oxygen delivery passages 108, 109, and consequentlyacross oxygen delivery valve 116. Optionally, pressure sensor 120 may beused to obtain reservoir pressure, and pressure sensor 114 may beeliminated. For example, when oxygen delivery valve 116 is closed,pressure upstream of the oxygen delivery valve correspond substantiallyto the pressure within reservoir 18.

Pressure sensor 120 may be coupled to controller 22, e.g., to providesignals that are processed by the controller to determine the pressuredifferential across the oxygen delivery valve. Controller 22 may usethis pressure differential to determine a flow rate of the oxygen beingdelivered from apparatus 10 or other parameters of oxygen beingdelivered. Controller 22 may change the frequency and/or duration thatoxygen delivery valve 116 is open based upon the resulting flow rates,e.g., based upon one or more feedback parameters, as described furtherbelow.

Oxygen sensor 118 may also be mounted to and/or below oxygen deliverymanifold 102 such that ports on oxygen sensor 118 communicate withoxygen sensor openings 130, 132. Oxygen sensor 118 measures the purityof oxygen passing therethrough. An example of such as device is anultrasonic sensor that measures the speed of sound of the gas passingthrough the oxygen sensor, such as those made by Douglas Scientific ofShawnee, Kans. Alternatively, oxygen sensor 118 may be a ceramic orsidestream sensor. Ultrasonic sensors may use less power than ceramicsensors, e.g., about fifty milliwatts (50 mW) versus one watt (1 W)),but may be more expensive.

Oxygen sensor 118 is coupled to controller 22 and generates electricalsignals proportional to the purity. These signals are processed bycontroller 22 and used to change the operation of apparatus 10, asdescribed further below. Because the accuracy of oxygen sensor 118 maybe affected by airflow therethough, it may be desirable to sample thepurity signals during no flow conditions, e.g., when oxygen deliveryvalve 116 is closed.

Pressure sensor 122 is mounted to and/or or below oxygen manifold 102such that the port of pressure sensor 122 communicates with pressuresensor opening 138. Pressure sensor 122 may be a piezo resistivepressure sensor capable of measuring absolute pressure. Exemplarytransducers that may be used include the Honeywell Microswitch 24PCOISMTTransducer, the Sensym SXOI, Motorola MOX, or others made by AllSensors. Because pressure sensor 122 may be exposed to the full systempressure of apparatus 10, it may be desirable for the over-pressurerating of pressure sensor 122 to exceed the full system pressure, e.g.,to be at least about fifteen pounds per square inch (15 psi).

Pressure sensor 122 is coupled to controller 22 so as to provide signalsproportional to the detected pressure. Because pressure sensor 122 maynot have a zero reference, the pressure signals from pressure sensor 122may drift during operation of the apparatus. To minimize any drift orother error introduced by pressure sensor 122, a small valve (not shown)may be coupled to pressure sensor 122 to periodically vent or zero thepressure sensor, e.g., when oxygen delivery valve 116 is open anddelivering oxygen.

Alternatively, a relative small orifice (e.g., about 0.010 inchdiameter) may be provided in the line between oxygen delivery valve 116(e.g., the normally open port), and pressure sensor 122. This orificemay be small enough not to adversely affect the pressure signals frompressure sensor 122, but large enough so that the pressure sensor isbled to zero, e.g., during a pulse as short as one hundred milliseconds(100 ms.). Additional information on using such an orifice may be foundin published application No. 2003/0150455, the entire disclosure ofwhich is expressly incorporated by reference herein. In anotheralternative, controller 22 implements a filtering algorithm to recognizethe beginning of the user's breath.

Manifold base 104 may include a recess 133 that communicates with oxygensensor opening 132 and pressure sensor opening 138. A cover or othermember not shown) may be attached over or otherwise cover the recess133, e.g., to provide a substantially airtight passage defined by therecess. Thus, pressure sensor 122 may measure an absolute pressure ofthe oxygen within recess 133. This pressure reading may be used todetect when a user is beginning to inhale, e.g., based upon a resultingpressure drop within recess 133, which may trigger delivering a pulse ofoxygen to the user, as explained further below.

Air filter 124 may be mounted to or adjacent oxygen delivery manifold102, and may include any conventional filter media for removingundesired particles from oxygen being delivered to the user. As bestseen in FIG. 9A, the oxygen delivery manifold 102 may include a recess137 shaped to receive air filter 124 therein. Air filter 124 may besecured within recess 137 by an interference fit, by one or moreconnectors, adhesives, and the like.

Recess 137 (shown in FIG. 9A) communicates with channel 135 (shown inFIG. 9B) via outlet opening 136. In the embodiment shown, channel 135extends between outlet openings 134, 136 formed in and through manifoldbase 104. A cover or other member (not shown) may be attached orotherwise cover channel 135, e.g., to provide a substantially airtightpassage defined by the channel. Thus, oxygen delivered from oxygensensor 118 may leave recess 133 though outlet opening 134, pass alongchannel 135, and enter recess 137 through outlet opening 136. The oxygenmay then pass through air filter 124 and be delivered to the user.

Optionally, a cannula barb 139 or other device is mounted to oxygendelivery manifold 102 over recess 137. Cannula barb 139 is attached tooxygen delivery manifold 102 using any conventional method, e.g., bymating threads, one or more detents or other connectors, adhesives, andthe like (also not shown). The cannula barb may include a nipple orother connector to which a cannula, e.g., flexible hose, and the like(also not shown), may be attached for delivering the oxygen to a user,as is known in the art. The cannula barb may be separate from air filter124, or the cannula barb and air filter 124 may be a single assemblythat is attached together to oxygen delivery manifold 102 over recess137.

It will be appreciated that other configurations and/or components maybe provided for delivering oxygen to the user, rather than oxygendelivery manifold 102 and the components attached thereto describedabove. In addition, although the components, e.g., oxygen delivery valve116, pressure sensors 120, 122, oxygen sensor 118, and air filter 124are described in a particular sequence (relative to oxygen flowingthrough the oxygen delivery manifold 102), the sequence of thesecomponents may be changed, if desired.

Returning to FIG. 2, controller 22 may include one or more hardwarecomponents and/or software modules that control one or more aspects ofthe operation of the apparatus 10. Controller 22 may be coupled to oneor more components of the apparatus 10, e.g., the compressor 14, aircontrol valves 20, oxygen delivery valve 116, pressure sensors 114, 120,122, and/or oxygen sensor 118. The components may be coupled by one ormore wires or other electrical leads (not shown for simplicity) capableof receiving and/or transmitting signals between the controller 22 andthe components.

Controller 22 may also be coupled to a user interface 144, which mayinclude one or more displays and/or input devices. In embodiment shownin FIG. 2, user interface 144 is a touch screen display that is mountedwithin or below interface window 142 in oxygen delivery manifold 102.User interface 144 displays information regarding parameters related tothe operation of apparatus 10 and/or allow the user to change theparameters, e.g., turn apparatus on and off, change dose setting ordesired flow rate, etc., as explained fuller below. Although a singleuser interface 144 is shown, it will be appreciated that the userinterface may include multiple displays and/or input devices, e.g.,on/off switches, dials, buttons, and the like (not shown). Userinterface 144 may be coupled to controller 22 by one or more wiresand/or other electrical leads (not shown for simplicity), similar to theother components.

For simplicity, controller 22 shown in FIG. 2 includes a singleelectrical circuit board that includes a plurality of electricalcomponents thereon. These components may include one or more processors,memory, switches, fans, battery chargers, and the like (not shown)mounted to the circuit board. It will be appreciated that controller 22may be provided as multiple subcontrollers that control differentaspects of the operation of apparatus 10. For example, a firstsubcontroller may control operation of motor 40 of compressor 14 and aircontrol valves 20, and a second subcontroller may control operation ofoxygen delivery valve 116 and/or user interface 144.

Controller 22, e.g., a first subcontroller that controls operation ofthe compressor 14, may include a brushless DC motor controller, such asone of the Motorola/ON MC33035 family, the Texas Instruments DSP TMS320LF240 and/or the MSP 430 F449IPZ. Such a controller may use utilizehall sensors (not shown) in the motor 40 to time commutation.Alternatively, a sensor-less controller may be used that allowscommutation timing via back-EMF measurement, i.e., the position of thearmature of the motor may be determined by the measurement of the backEMF of the coils of the motor. This alternative may be less expensive,because the sensors in the motor may be eliminated, and the wiring tothe motor may be simplified. For example, Fairchild may have a dedicatedintegrated circuit appropriate for use in the controller 22.Alternatively, a Texas Instruments DSP TMS 320LF240 or the MSP 430F449IPZ microprocessor may be used that includes integrated sensor-lesscontrol peripherals.

The first subcontroller (or other component of controller 22) maycontrol a speed of the motor, and consequently, a pressure and/or flowrate of compressed air delivered by diaphragm assemblies 46. Controller22 may also control the sequence of opening and closing the air controlvalves 20, e.g., to charge and purge sieve beds 12 in a desired manner,such as the exemplary methods described further below.

The second subcontroller (or other component of controller 22) maycontrol oxygen delivery valve 116, e.g., to deliver oxygen fromreservoir 18 to a user based upon pressure signals received frompressure sensor 122. The second subcontroller may also receive inputinstructions from the user and/or display information on user interface144. In addition, the subcontrollers or other components of controller22 may share information in a desired manner, as described below. Thus,controller 22 may include one or more components, whose functionalitymay be interchanged with other components, and the controller should notbe limited to the specific examples described herein.

In addition, apparatus 10 may include one or more power sources, coupledto controller 22, compressor 14, air control valves 20, and/or oxygendelivery valve 116. For example, as shown in FIG. 2, a pair of batteries148 are provided that mount or otherwise secure to air manifold 16,e.g., along the open sides between side walls 59, 159 and sieve beds 12.Air manifold 16 may include one or more mounts 149 that are received inbatteries 148, e.g., to stabilize and/or otherwise secure the batteriesvertically within apparatus 10. In addition or alternatively, otherstraps or supports (not shown) may also be used to secure the batteries148 within the apparatus.

In exemplary embodiments, batteries 148 are rechargeable batteries, suchas eleven (11) volt nominal 3 series Li-Ion batteries, 4 series Li-Ionbatteries (such as those available from Inspired Energy, e.g., Par No.NL2024), and the like. For 3 series packs, standard one pound (lb) packsmay have a current limitation of three (3) amperes, while one and a halfpound (1.5 lb.) packs may have a maximum current of six (6) amperes.Additional information on Inspired Energy batteries that may be used maybe found at ww.inspired-energy.com. Other sources of batteries mayinclude Molien Energy (www.molienergy.com), GP Batteries(www.gpbatteries.com), Micro-Power (www.micro-power.com), and Buchmann(www.buchmann.ca).

Controller 22 controls distribution of power from batteries 148 to othercomponents within apparatus 10. For example, controller 22 may drawpower from one of the batteries until its power is reduced to apredetermined level, whereupon the controller may automatically switchto the other of the batteries. Alternative, the present inventioncontemplates that controller 22 causes both batteries to dischargeequally.

Optionally, apparatus 10 may include an adapter so that an externalpower source, e.g., a conventional AC power source, such as a walloutlet, or a portable AC or DC power source, such as an automotivelighter outlet, a solar panel device, and the like (not shown) can beused to provide power to the apparatus. Any transformer or othercomponents (also not shown) necessary to convert such externalelectrical energy such that it may be used by apparatus 10 may beprovided within the apparatus, in the cables connecting the apparatus tothe external power source, or in the external device itself.

Optionally, controller 22 may direct some electrical energy fromexternal sources back to batteries 148 to recharge them in aconventional manner. The controller may also display the status of theelectrical energy of the apparatus, e.g., automatically or upon beingprompted via user interface 144, such as the power level of batteries148, whether apparatus 10 is connected to an external power source, andthe like. Controller 22 may include one or more dedicated components forperforming one or more of these functions. An exemplary batterymanagement integrated circuit (“IC”) that may be included in controller22 is the Maxim MAX 1773 type, which is designed for dual batterysystems (see, e.g., www.maxim-ic.com/quick_view2.cfin/qv_pk/2374 formore information). Another is the Linear LTC 1760, which is alsodesigned for dual battery systems and combines similar selectorfunctions with charging (see, e.g.,www.linear.com/prod/dataheet.html?datasheet=989 for more information).

F. Assembly

Returning to FIGS. 1A-3, to assemble apparatus 10, the components of airmanifold 16 and oxygen manifold 102 may be manufactured and assembled,as described above. For example, manifold bases 58, 104, manifold caps60, 106, and/or other caps or covers (not shown) may be molded orotherwise manufactured, and manifold caps 60, 106, and/or other caps orcovers (not shown) may be attached to manifold bases 58, 104, e.g.,using one or more of cooperating detents, connectors, fasteners,interference fit, adhesives, and the like (not shown). Similarly, sievebeds 12, reservoir 18, and compressor 20 may be manufactured and/orassembled, e.g., as described above.

Air control valves 16, sieve beds 12, reservoir 18, and/or compressor 20may be mounted to air manifold 16, e.g., to the manifold cap 60, also asdescribed above. Similarly, oxygen delivery valve 116, pressure sensors120, 122, oxygen sensor 118, air filter 124, and/or other components maybe mounted to oxygen delivery manifold 102. Oxygen delivery manifold 102may be attached to the sieve beds 12 and reservoir 18, e.g., after orbefore the sieve beds and reservoir are attached to air manifold 16. Theorder of assembly is not important and may be changed to facilitatedesired manufacturing facilities and/or procedures.

Simultaneously or separately, side walls 59, 159 may be attached to oneanother, or, if side walls 59, 159 are one or more separate panels (notshown), they may be attached to and/or between air manifold 16 andoxygen delivery manifold 102. The resulting structure may provide astructural frame for apparatus 10 that may eliminate the need foradditional supports or structural or cosmetic outer skins.

Controller 22, which is provided on a circuit board, is mounted withinthe structural frame and any wires or other leads are connected betweenthe controller and the other components coupled thereto. In an exemplaryembodiment, controller 22 (or at least one subcontroller) is mounted toair manifold 16, e.g., vertically adjacent exhaust opening(s) 92. Thus,the gas exiting the air manifold, e.g., concentrated nitrogen, may bedirected across or otherwise towards the controller for cooling itscomponents. Brackets or other supports (not shown) may be mounted tomanifold cap 60 and the circuit board(s) and/or other components ofcontroller 22 may be secured by the brackets or support in aconventional manner.

Batteries 148 are inserted into the apparatus 10 at any time, e.g.,after access to the interior is no longer needed. The side regionsbetween manifolds 16, 102 may remain substantially open (other than anyarea covered by batteries 148), e.g., to provide access during assemblyand/or testing of the components of the apparatus. Optionally, arelatively thin and/or light-weight skin or other structure (not shown)may be provided in each of the open side regions to substantiallyenclose the interior of the apparatus 10, e.g., to limit access and/orprotect the components therein, or reduce noise transmission and soundlevel.

G. Operation of the Apparatus

Returning to FIG. 3, the basic operation of apparatus 10 will now bedescribed. Generally, the operation of the apparatus has two aspects,concentrating oxygen from ambient air by adsorption within the sievebeds, and delivering concentrated oxygen to a user from the reservoir,each of which is described below. Each aspect of the apparatus mayoperate independently of the other, or they may be interrelated, e.g.,based upon one or more related parameters.

Apparatus may be operated using one or more optional methods, such asthose described below, to increase efficiency or other performancecharacteristics of the apparatus. For example, based upon measurementsof pressure and/or oxygen purity, the operating conditions of theapparatus may be adjusted to increase oxygen purity and/orconcentration, output flow rate and/or pressure, reduce powerconsumption, and the like.

In exemplary embodiments, apparatus 10 has the capability to deliver upto about 0.9 or 1.2 liters per minute (lpm) equivalent of pure oxygen.As used herein, equivalent flow rates are used, which correspondsubstantially to the amount of pure (100%) oxygen gas delivered per unitof time. Because apparatus 10 concentrates oxygen by adsorption fromambient air, the apparatus does not generate pure oxygen for delivery toa user. Instead, the gas that escapes from sieve beds 12 that is storedin reservoir 18 has a maximum concentration of oxygen of about ninetyfive percent (95.4%), with the rest of the gas being argon and othertrace gases (about 4.6%).

At a given flow rate, the actual amount of concentrated oxygen deliveredby apparatus 10 may be less than for pure oxygen. Thus, concentratedoxygen may have less therapeutic value than pure oxygen. To compensatefor this deficit and provide equivalent volumes of oxygen, the flow rateof concentrated oxygen must be higher than for pure oxygen. The Ratio ofdelivered concentrated oxygen to equivalent pure oxygen is expressed inEquation (1) below:Ratio=(100%−21%)/(actual purity−21%),   (1)and is as shown in FIG. 12. For example, 1.05 lpm of 88% concentratedoxygen may be substantially equivalent to 0.9 lpm of pure oxygen, and1.4 lpm of 88% concentrated oxygen may be substantially equivalent to1.2 lpm of pure oxygen.

Testing has shown that compensating for purity by increasing the flowrate may reduce overall power consumption for apparatus 10. For example,FIGS. 13 and 14 illustrate the relationship between power consumptionand the purity of the oxygen output by apparatus 10. More specifically,FIG. 13 shows the relationship between the total power consumed by thedevice at different levels of oxygen purities, and FIG. 14 shows therelationship between the power consumed only by compressor 14 atdifferent levels of oxygen purities. Curves 181, 182, and 183 representthe total power versus oxygen purity relationship at various flowsettings. Curve 181 corresponds to a flow setting of 2, which isequivalent to 400 cubic centimeters (cc) of oxygen per minute, curve 182corresponds to a flow setting of 3, which is equivalent to 600 cc/min,and curve 183 corresponds to a flow setting of 4.5, which is equivalentto 900 cc/min. Curves 184, 185, and 186 represent the total power versusoxygen purity relationship at various flow settings. Curve 184corresponds to a flow setting of 2 (300 cc/min), curve 185 correspondsto a flow setting of 3(600 cc/min), and curve 186 corresponds to a flowsetting of 4.5 (900 cc/min).

It can be appreciated from reviewing FIGS. 13 and 14 that as the oxygenpurity increases, the power needed to make the oxygen increasesexponentially. At some point, it becomes too “costly” in terms of powerconsumption to generate higher purities of oxygen. Similarly, as theoxygen purity is decreased from approximately 87-90%, relatively littlepower consumption is gained. That is, further decreases in oxygen puritybelow 87-90% do not provide much benefit in terms if power consumption,i.e., longer battery duration. Stated another way, there are diminishingmarginal returns in terms of power consumption for decreases in oxygenpurity beyond 87-90%. The present inventors determined that when thecompeting values of oxygen purity and power consumption are balanced,oxygen purities between about 85-90% result in desirable efficiencies,with 88% being deemed an exemplary target oxygen purity for the gasdelivered by apparatus 10.

FIG. 15 illustrates the relationship between the amount of oxygenproduced and the oxygen purity. Curve 187 represents the 100% oxygenequivalent or molecules of oxygen generated over a range of puritylevels. It can be appreciated from this figure that as the oxygen purityincreases, for example, above 90-91%, less molecules of oxygen are madeby apparatus 10. Similarly, as the purity is reduced, e.g., below87-88%, there is very little additional molecules of oxygen generated.Stated another way, there are diminishing marginal returns in terms ofoxygen generated for purities below 87-88%. Thus, the present inventorsdeemed that the ideal “sweet spot” in terms of oxygen purity is in arange of 85-90%.

FIG. 16 is a table of the data used to generate the curves in FIGS.13-15. It should also be notes that volts and amps used by the systemwithout the compressor operating but with the cooling fan (intake fan164) operating is: V=18.1 V, A=0.31 A, for a total power of 5.6 W.Without the compressor or the cooling fan operating, the volts and ampsused by the system is: V=18.1 V, A=0.14 A, for a total power of 2.5 W.Thus, the fan alone uses approximately 3.1 W of power.

1. Driving the Sieve Beds

Generally, to generate concentrated oxygen, which may be stored inreservoir 18 and/or delivered directly to the user, apparatus 10 isoperated such that sieve beds 12 are alternatively “charged” and“purged.” When a sieve bed is being charged or pressurized, compressedambient air is delivered from the compressor into air inlet/outlet end32 of the sieve bed, causing the sieve material to adsorb more nitrogenthan oxygen as the sieve bed is pressurized. While the nitrogen issubstantially adsorbed by the sieve material, oxygen escapes throughoxygen inlet/outlet end 34 of the sieve bed, where it may be stored inthe reservoir and/or be delivered to the user.

Once the pressure within the sieve bed reaches a predetermined limit (orafter a predetermined time), the sieve bed may then be purged orexhausted, i.e., air inlet/outlet end 32 may be exposed to ambientpressure. This causes the compressed nitrogen within the sieve bed toescape through air inlet/outlet end 32, e.g., to pass through airmanifold 16 and exit exhaust opening(s) 92. Optionally, as the sieve bed12A is being purged, oxygen escaping from the other sieve bed 12B (whichmay be being charged simultaneously) may pass through purge orifice 81into oxygen inlet/outlet end 34 of purging sieve bed 12A, 12B, e.g., ifthe pressure within the charging sieve bed is greater than within thepurging sieve bed, which may occur towards the end of purging. Inaddition or alternatively, oxygen may pass through check valves 110between the sieve beds, e.g., when the relative pressures of the sievebeds and the reservoir causes check valves 110 to open, in addition toor instead of through purge orifice 81. This oxygen delivery into oxygeninlet/outlet end 34 of sieve bed being purged may assist evacuating theconcentrated nitrogen out of the sieve bed before it is charged again.

The size of purge orifice 81 is selected to allow a predetermined oxygenflow rate between the charging and purging sieve beds 12. It isgenerally desirable that the flow through the purge orifice is equal inboth directions, such that both sieve beds 12A and 12B re equallypurged, e.g., by providing a purge orifice having a geometry that issubstantially symmetrical. In an exemplary embodiment, purge orifice 81may have a diameter or other equivalent cross-sectional size of about0.02 inch (0.5 mm) such that about 2.6 lpm may pass therethrough atabout five pounds per square inch (5 psi) pressure difference across thepurge orifice. This capacity of purge orifice 81 may not correspond tothe actual volume of oxygen that may flow between the sieve beds duringoperation of the apparatus, because the actual flow may be based of thepressure difference between the charging and purging sieve beds 12,which changes dynamically based upon the various states of theapparatus.

In an exemplary embodiment, shown in Table 1 below, apparatus 10 isoperated using a process that includes four (4) states “1” and “0”represent open and closed states of air control valves 20, respectively.

TABLE 1 Valve Valve Valve Valve State Time Description 20a_(s) 20a_(e)20b_(s) 20b_(e) 1 Time Pressurize Pressurize 12A 1 0 0 1 ~6 sec. Exhaust12B 2 Time Overlap Pressurize both 1 0 1 0 ~0.2 sec 12A and 12B 3 TimePressurize Pressurize 12B 0 1 1 0 ~6 sec. Exhaust 12A 4 Time OverlapPressurize both 1 0 1 0 ~0.2 sec 12A and 12B

During state 1, sieve bed 12A is being charged and sieve bed 12B isbeing purged. As shown in the table, supply air control valve 20 a _(s)and exhaust air control valve 20 b _(e) are open, and supply air controlvalve 20 b _(s) and exhaust air control valve 20 a _(e) are closed. Withadditional reference to FIG. 7, with this valve arrangement, sieve bed12A communicates with compressor 14 via compressor outlet passage 64 andsieve passage 66 a, while sieve bed 12B communicates with exhaustopening(s) 92 via sieve bed passage 66 b and exhaust passage 68. At theend of state 1, as the pressure within sieve bed 12A exceeds thepressure within sieve bed 12B, purge orifice 81 provides a low flow ofoxygen gas to flush remaining nitrogen from sieve bed 12B. State 3 isthe mirror image of State 1, i.e., sieve bed 12B is being charged andsieve bed 12A is being purged.

The duration of States 1 and 3 (Time Pressurize) may be set based uponone or more parameters, such as the size of purge orifice 81, the purityof oxygen leaving sieve beds 12, pressure within reservoir 18, and thelike, as described further elsewhere herein. For example, during State1, if Time Pressurize is too long, all remaining nitrogen in sieve bed12B (which is being purged) may be purged, and oxygen from sieve bed 12A(which is being charged) passing through the purge orifice 81 into sievebed 12B may escape out the exhaust opening(s) 92, wasting oxygen. IfTime Pressurize is too short, nitrogen may remain in sieve bed 12B atthe end of the purge cycle, which may reduce the efficiency of sieve bed12B when it is subsequently charged. Thus, it may be desirable to holdthe size of purge orifice 81 to a very tight flow tolerance, andmanufacture sieve beds 12 under strict control, such that the sieve bedsis consistent within allowable tolerances without having to adjust TimePressurize during and/or after manufacturing.

During State 2, supply air control valve 20 b _(s) is opened and exhaustair control valve 20 a _(e) is closed. This allows pressurized air fromsieve bed 12A to flow into sieve bed 12B through the purge orifice 81.Generally, State 2 is relatively short compared to States 1 and 3, e.g.,such that pressurized air enters sieve bed 12B before concentratednitrogen within sieve bed 12A begins to enter sieve bed 12B. State 2 mayreduce the amount of compressed air that must be delivered from thecompressor 14 before State 3, which may improve overall efficiency ofthe apparatus 10. Similarly, during State 4, supply air control valve 20a _(s) is opened and exhaust air control valve 20 b _(e) is closed.Thus, during State 4, compressed air flows from sieve bed 12B to sievebed 12A before sieve bed 12A is charged (when State 1 is repeated).

In the embodiment shown in Table 1 above, the durations (Time Overlap)of States 2 and 4 are substantially shorter than the durations (TimePressurize) of States 1 and 3. For example, the durations (Time Overlap)of States 2 and 4 may be not more than about 1.5 seconds or not morethan about 0.6 second, while the durations (Time Pressurize) of States 1and 3 may be at least about four (4) seconds or at least about five (5)seconds.

Optionally, the durations may be varied, for example, as user demand(e.g., dose setting and/or breathing rate) and/or other parameterswarrant the change(s). Alternatively, the durations (Time Pressurize andTime Overlap) may be fixed when the controller 22 is initiallyprogrammed and/or subsequently serviced. In either case, times or timeconstants may be saved in flash-type memory or other memory associatedwith controller 22. If desired, the times or time constants may beadjusted, e.g., via a serial connection during initial manufacturing, ina subsequent service environment, and/or during use, and the new valuesmay be stored within the memory.

For example, it may be desirable to reduce the durations of States 1 and3 (Time Pressurize) as the pressure within the reservoir 18 (“reservoirpressure” or P_(res)) increases. As the reservoir pressure increases,the higher pressure may drive more gas through purge orifice 81,reducing the amount of time required to substantially exhaust nitrogenfrom sieve bed 12A, 12B being purged. An equation may be created todetermine the optimum time (Time Pressurize) based upon the reservoirpressure. For example, the equation may be estimated based upon a linearrelationship:Time Pressurize=k*P_(res),   (2)where k is a constant that may be determined theoretically orempirically. Alternatively, a more complicated equation may bedeveloped, e.g., based upon empirical testing. The duration of States 2and 4 (Time Overlap) may also be fixed or adjusted during manufacturingor servicing, and/or dynamically during operation of apparatus 10, ifdesired, in a similar manner.

Optionally, one or more check valves (not shown) may be provided in theexhaust line (e.g., within exhaust passage 68 in air manifold 16 orcoupled to the exhaust opening(s) 92). Such a check valve may stop sievebeds 12 from “breathing,” e.g., when apparatus 10 is not operational,and is subjected to changing barometric pressure and/or temperature. Forexample, if SMC DXT valves are provided for exhaust air control valves20 _(e), they may act as check valves. Without pilot pressure, however,exhaust air control valves 20 _(e) may leak. Relatively small springs(not shown) may be added to these valves to prevent such leakage.

Alternatively, one or more valves (not shown) may be provided inparallel with or instead of purge orifice 81, i.e., in lines extendingbetween the oxygen inlet/outlet ends 34 of sieve beds 12. In thisalternative, apparatus 10 may be operated using a four (4) state cyclesimilar to that described above. However, the parallel valves may openduring the overlap time or at the end of the pressure cycle in order toactively control pressurization or purging of sieve beds 12.

The technique used to determine the target pressure and valve timing,i.e., the duration of the charge/purge cycles, according to theprinciples of the present invention are discussed below with referenceto FIGS. 17-20. As used below “Valve Time” refers to the during of thecharge cycle or the purge cycle. The present invention sets the valvetiming so as to achieve the beneficial features of the presentinvention, namely a light-weight, high-output, long battery life,ambulatory oxygen concentrator. The Valve Time is optimized empiricallyat different oxygen production levels. Higher pressure in the sieve bedsyields a shorter ideal valve time. It is believed that this is becausethe higher pressure generates higher flows through the purge orifice,which purges the exhausting bed faster.

As shown in FIG. 17, the Valve Time is determined in step 290 by firstdetermining the pressure of the product tank/reservoir 18, which isdetermined based on the output of pressure sensor 114. It should benoted that tank/reservoir 18 is used in place of the sieve bed pressurebecause they are substantially the same. Of course, the sieve bedpressure could also be used. In step 292, the Valve Time (ms) isdetermined according to the relationship between valve time andpressure, which is graphically illustrated in FIG. 18 as curve 294. Theequation that defines the Valve Time and that corresponds to curve 294is defined as follows:Valve Time (ms)=9000−Pressure×300,   (3)In step 296, the Valve Time computed in step 232 is low pass filter tostabilize its value over a period of time and the Valve Time is providedin step 298. The purpose of the low pass filtering the Valve Time is toprevent it from changing too abruptly, as this can lead to instabilityand poor system performance. Thus, the charge time and the purge timeare set based on the Valve Time determined in step 298.

Between each bed cycle, there is a short (˜400 ms) time when bothpressurize valves are open and both exhaust valves are closed. Thisallows pressurized air, not depleted of oxygen yet, to be transferredfrom the bed coming off of its pressurize cycle to the bed just startingits cycle, reducing the required compressor airflow and hence power.Currently, this time is fixed, but it could be adjusted slightlyrelative to system pressure for optimized performance.

Because the sieve beds can get out of balance for a variety of reasons,e.g., purge orifice non-symmetry, different sieve packing, process valveperformance etc., and because this may be damaging to systemperformance, the present invention contemplates monitoring the peakproduct tank pressure in each sieve bed and tracking the peak ratio ofthese peak pressures. Peak product tank pressure is chosen in anexemplary embodiment of the present invention because the averageproduct tank pressure during each phase may not be as indicative ofsieve bed pressure. During the first portion of each phase, the producttank pressure is more affected by the previous bed's pressure, not thecurrent one.

In conventional concentrators, product tank pressure has been used asthe trigger to shift cycles instead of time. This compensates for thedifferences in the sieve beds. This may not work in the portable oxygenconcentrator of the present invention because the present invention hasa variable concentrator output. In the present invention, the Valve Timewill need to be adjusted, for example to make it shorter when thepressure is higher. If pressure is used to switch bed phases, theprevent invention would not likely be able to use pressure to controlthe compressor motor voltage. Motor speed would sit low, for example,and the Valve Time would get as long as necessary to achieve the targetpressure.

The present invention contemplates using a proportional integral controlloop to adjust the Valve Time to bring the peak ratio toward unity (1).If a first sieve bed is running at a higher peak pressure than thesecond sieve bed, the Valve Time for the first sieve bed is shortened tobring the peak pressures close together.

2. Oxygen Delivery to User

With concentrated oxygen stored in the reservoir 18 and/or with thesieve beds 12A, 12B separating oxygen from ambient air, the apparatus 10may be used to deliver concentrated oxygen to a user. As describedabove, controller 22 may be coupled to oxygen delivery valve 116 foropening and closing the oxygen delivery valve to deliver oxygen fromreservoir 18 to a user of apparatus 10.

In an exemplary embodiment, controller 22 may periodically open theoxygen delivery valve 116 for predetermined “pulses.” During pulsedelivery, a “bolus” of oxygen is delivered to the user, i.e., oxygendelivery valve 116 is opened for a predetermined pulse duration, andthereafter closed until the next bolus is to be delivered.Alternatively, controller 22 may open oxygen delivery valve 116 forcontinuous delivery, e.g., throttling the oxygen delivery valve toadjust the flow rate to the user. In a further alternative, controller22 may periodically open and throttle oxygen delivery valve 116 for apredetermined time to vary the volume of the bolus delivered.

In one embodiment, controller 22 may open oxygen delivery valve 116after the controller detects an event, such as detecting when the userbegins to inhale. When the event is detected, oxygen delivery valve 116may be opened for the predetermined pulse duration. In this embodiment,the pulse frequency or spacing (time between successive opening of theoxygen delivery valve) may be governed by and correspond to thebreathing rate of the user (or other event spacing). The overall flowrate of oxygen being delivered to the user is then based upon the pulseduration and pulse frequency.

Optionally, controller 22 may delay opening oxygen delivery valve 116for a predetermined time or delay after the user begins to inhale, e.g.,to maximize delivery of oxygen to the user. For example, this delay maybe used to maximize delivery of oxygen during the “functional” part ofinhalation. The functional part of the inhalation is the portion wheremost of the oxygen inhaled is absorbed into the bloodstream by thelungs, rather than simply used to fill anatomical dead space, e.g.,within the lungs. It has been found that the functional part ofinhalation may be approximately the first half and/or the first sixhundred milliseconds (600 ms) of each breath. Thus, the predetermineddelay after detecting inhalation may be between about twenty and onehundred fifty milliseconds (20-150 ms).

Thus, it may be particularly useful to detect the onset of inhalationearly and begin delivering oxygen quickly in order to deliver oxygenduring the functional part of inhalation. A user breathing through theirnose may generate relatively strong pressure drops, e.g., about onecentimeter of water (1 cmH₂O), within the cannula. However, if the userbreathes through their mouth, they may only generate pressure drops onthe order of 0.1 centimeter of water (0.1 cmH₂O).

For example, assuming an excitation voltage of five volts (5 V), theoutput sensitivity of the pressure sensor 122 may be about 320 μV/cmH₂O.Consequently, a pressure drop of 0.1 V (e.g., from inhalation throughthe mouth ). If the controller 22 includes an amplifier (not shown)having a gain of one thousand (1,000), the amplifier would create anamplified signal of about thirty-two millivolts (32 mV), which mayprovide six (6) counts in a ten (10) bit five volt (5 V) analog todigital (A/D) converter.

As explained above, pressure sensor 122 may exhibit drift problems,making it difficult for controller 22 to identify the beginning of aninhalation and open oxygen delivery valve 116. One solution is to resetor zero pressure sensor 122 when apparatus 10 is off. However, thepressure sensor may be temperature sensitive such that the pressuresensor may create a drift greater than the trigger level. Alternatively,as described above, a small valve (not shown) may be coupled to pressuresensor 122 that may be opened periodically to reset or zero the pressuresensor, e.g., while oxygen delivery valve 116 is open and deliveringoxygen. In a further alternative, also described above, a relativelysmall orifice may be provided between pressure sensor 122 and oxygendelivery valve 116 that may allow the pressure sensor to reset or zeroduring oxygen delivery, e.g., during a pulse as short as one hundredmilliseconds (100 ms).

In yet a further alternative, controller 22 includes hardware and/orsoftware that filters the signals from pressure sensor 122 to determinewhen the user begins inhalation. In this alternative, controller 22 mayneed to be sufficiently sensitive to trigger oxygen delivery valve 116properly, e.g., while the user employs different breathing techniques.For example, some users may practice pursed lip breathing, e.g.,inhaling through their nose and exhaling through pursed lips. Duringthis breathing technique, controller 22 will not detect an expiratorysignal that will indicate that inhalation is about to begin.

The filtering algorithm may also need to distinguish between the onsetof inhalation and a declining rate of exhalation, which may otherwisemislead the controller into triggering oxygen delivery during a longperiod of exhalation (which is wasteful). In addition or alternatively,the filtering algorithm of controller 22 may need to “hold off” duringlong breaths, e.g., to avoid delivering multiple pulses during arelatively long single inhalation. For example, if the controller isconfigured to open oxygen delivery valve 116 if it detects a pressuredrop below a predetermined threshold, it may open the oxygen deliveryvalve twice during a single inhalation (which may also be wasteful). Inthis situation, the filtering algorithm time after inhalation is sensed,e.g., at least about 1.5 seconds.

Alternatively, controller 22 may open the oxygen delivery valve at apulse frequency that is fixed, i.e., independent of the user's breathingrate, or that may be dynamically adjusted. For example, the controllermay open oxygen delivery valve 116 in anticipation of inhalation, e.g.,based upon monitoring the average or instantaneous spacing or frequencyof two or more previous breaths. In a further alternative, thecontroller may open and close oxygen delivery valve 116 based upon acombination of these parameters, e.g., based upon the user's breathingrate, but opening the oxygen delivery valve if a minimum predeterminedfrequency is not met.

For pulse delivery, the pulse duration may be based upon the dosesetting selected by the user. In this way, substantially the same volumeof oxygen may be delivered to the user each time oxygen delivery valve116 is opened, given a specific dose setting. The dose setting may be aquantitative or qualitative setting that the user may select. Aqualitative dose setting may involve a dial or one or more buttons(e.g., on user interface 144) that allows the user to select a level,e.g., on a scale from one to ten (1-10) or from range between a minimumand a maximum value. Controller 22 may relate the qualitative settingwith a desired flow rate or bolus size, e.g., relating to the maximumflow capacity of apparatus 10.

For example, the settings may correspond to points within the range atwhich the apparatus 10 may supply concentrated oxygen, e.g., betweenzero and one hundred percent (0-100%) of a maximum capacity of theapparatus. For example, a maximum flow rate (or equivalent flow rate ofpure oxygen) for apparatus 10 may be used, e.g., between about six andsixteen liters per minute (6-16 lpm). Alternatively, a maximum bolusvolume may be used, e.g., between about ten and one hundred fiftymilliliters (10-150 ml) or between about ten and eighty milliliters(10-80 ml).

A quantitative setting may allow a user to select a desired flow rate(e.g., in lpm), which may be an actual concentrated oxygen flow rate oran equivalent pure oxygen flow rate, or a desired bolus volume (e.g., inmilliliters). The flow rates or volumes available for selection may alsobe limited by the capacity of the apparatus 10, similar to thequalitative settings. Additional information on using a volume-baseddose setting system, rather than implying equivalency to continuousflow, may be found in Characteristics of Demand Oxygen Delivery Systems:Maximum Output and Setting Recommendations, by P. L. Bliss, R. W. McCoy,and A. B. Adams, Respiratory Care 2004; 49(2) 160-165, the entiredisclosure of which is incorporated by reference herein.

As the dose setting is increased, the pulse duration may be increased,e.g., from about fifty to five hundred milliseconds (50-500 ms) todeliver a predetermined bolus during each pulse. If the user's breathingrate remains substantially constant, the pulse frequency may also remainsubstantially constant, thereby increasing the overall flow rate beingdelivered to the user. During actual use, however, the user's breathingrate may change, e.g., based upon level of activity, environmentalconditions, and the like. For example, breathing rates for lung diseasepatients may vary from about thirteen to forty (13-40) breaths perminute, or from about eighteen to thirty (18-30) breaths per minute.Therefore, apparatus 10 may be capable of delivering these frequenciesof pulses to the user.

Because of the relatively small size of a portable concentrator, such asapparatus 10, conditions may occur in which the dose setting and user'sbreathing rate exceed the capacity of the apparatus. Thus, for any givendose setting, i.e., particular volume (e.g., ml) per breath, theapparatus may have a maximum breathing rate at which the apparatus maydeliver oxygen at the desired dose setting.

If the maximum breathing rate for a particular dose setting is exceeded,the apparatus may respond in one or more ways. For example, apparatus 10may include an alarm, e.g., a visual and/or audio alarm, that may alertthe user when such an event occurs. This may alert the user, and, ifnecessary, the user may slow their breathing rate, e.g., by resting andthe like.

In addition or alternatively, apparatus 10 may change the deliveryparameters to maintain delivery at or near the maximum flow ratecapacity of the apparatus, e.g., about 900 ml/min. or about 1,200ml/min. To achieve this, controller 22 calculates the bolus size thatmay be delivered given the user's breathing rate (e.g., dividing themaximum flow rate by the breathing rate or using a lookup table), andadjust the pulse duration accordingly (and/or throttle oxygen deliveryvalve 116). For example, assume controller 22 detects that the user hasa breathing rate of about twenty-three (23) breaths per minute over apredetermined time, e.g., the most recent thirty seconds (30 sec), andthe dose setting delivers forty millimeters (40 ml) per breath. Theresulting flow rate, 920 ml /min, would exceed the ability of a 900ml/mi. capacity apparatus. Consequently, controller 22 may reduce thepulse duration to reduce the flow rate at or below 900 ml /min, e.g., byreducing the pulse duration by at least about (1900/920) or about twopercent (2%).

When selecting volumetric flow rates for pulse delivery, one or moreadditional factors may also be considered. For example, higher flowrates may create greater back pressure in the cannula, making control ofthe flow more difficult, especially in a relatively low pressure system,such as a portable oxygen concentrator, similar to apparatus 10described herein.

Optionally, apparatus 10 may be operated in a manner that may maximizeefficiency, 10 e.g., to reduce power consumption and extend battery lifeof the apparatus. This may enhance the mobility of the user, e.g.,allowing them to remain independent of an external power source forlonger periods of time.

Several variables may be relevant to determine how much energy may berequired to operate apparatus 10. The independent variable is the speedor power of compressor 14, which may consume as much as ninety fivepercent (95%) of the power used by the apparatus. The speed of motor 40of the compressor may be controlled by controller 22, and is essentiallya pulse width modulation (“PWM”) of the power of battery 148, i.e., themore power required, the higher the duty cycle of the PWM.

Closed loop speed or torque control of motor 40 may be used, but may notbe necessary. During the process cycle, as pressure increases, the speedof the motor of compressor 14 may be reduced because of the highertorque requirement. This may result in the total energy required beingsubstantially leveled, minimizing current peaks.

During the process cycle, when the sieve bed feed valve is open and thepressure of the sieve bed/product tank increases toward the targetpressure, the motor is not controlled to a fixed speed. Instead, themotor speed is allowed to fall, but the current/power provided to themotor is limited. By limiting current/power to the motor, this maximizesthe consumption of the battery, i.e., battery life. This is so, becausethe discharge current rate of the battery is lowered and therefore therun time of the battery of the enhanced/maximized.

The PWM may be expressed as a percentage from zero to one hundredpercent (0-100%), zero corresponding to compressor 14 being off and onehundred percent corresponding to the compressor operating at its maximumspeed. In practice, there is a minimum value attainable, below whichcompressor 14 may not turn, and therefore, the true range may be aboutforty to one hundred percent (40-100%). The equations here assume therelationships are linear, which may provide sufficient approximation.Alternatively, more detailed equations may be developed based upontheoretical or empirical calculations, e.g., which may be implementedusing a non-linear equation or a lookup table, e.g., within memory ofcontroller 22.

PWM may be controlled by monitoring reservoir pressure (pressure withinreservoir 18) and controlling motor 40 of the compressor to maintain atarget reservoir pressure. For example, controller 22 may be coupled topressure sensor 114 within the reservoir to monitor the reservoirpressure, and the controller may adjust the PWM of the motoraccordingly. The target reservoir pressure may be static, e.g., setduring manufacturing or service, or may be dynamic, e.g., changed tomaintain a target oxygen purity and/or other parameter(s), as describedfurther elsewhere herein. Alternatively, multiple variables may bemonitored and motor 40 controlled to maintain the multiple variables atselected targets.

For example, a target reservoir pressure may be selected based upon dosesetting and user breathing rate. In exemplary embodiments, the targetreservoir pressure is between about five and fifteen pounds per squareinch (5-15 psi) or between about six and twelve pounds per square inch(6-12 psi). Optionally, the target pressure may be adjusted based uponother parameters, such as oxygen purity, as explained further below.

The user breathing rate may be determined by controller 22, e.g., basedupon pressure readings from pressure sensor 122. The pressure sensor maydetect a reduction in pressure as the user inhales (e.g., drawing oxygenfrom recesses 133, 137 and channel 135, shown in FIGS. 9A and 9B).Controller 22 may monitor the frequency at which pressure sensor 122detects the reduction in pressure to determine the breathing rate. Inaddition, the controller may also use the pressure differential detectedby pressure sensor 120.

As the dose setting is increased, the user breathing rate increases,and/or the battery voltage drops, the product reservoir pressure maytend to drop. To compensate for this pressure drop, PWM may beincreased. Thus, a target reservoir pressure may be chosen andcontroller 22 may implement a control loop to maintain this targetreservoir pressure.

FIG. 19 illustrates an example of a process apparatus 10 uses to controlthe speed of motor 40 in compressor 14. The present invention controlsthe speed of motor 40 so as to maintain an averaged Target Pressure inproduct tank or reservoir 18. It should be noted that the motor speed isnot sensed or determined, if monitored at all, it is done only forinformational purposes. It should also be noted that the motor speed,per se, is not being controlled. Instead, the process illustrated inFIG. 19 is used to adjust the voltage provided to the motor, which mayor may not change the motor speed, depending, for example, in the torquethe motor is experiencing.

In step 300, oxygen demand (minute volume) is determined by the pulse ordose setting and averaged patient breathing rate. In step 302, minutevolume is used to calculate the target product tank pressure (“TargetPressure”) according to the relationship given in this step. Thisrelationship between minute volume and the Target Pressure is showngraphically in FIG. 20 as curve 303. A higher Target Pressure isrequired for higher oxygen production. The Target Pressure has beendetermined empirically to be high enough, with some safety factor, toproduce oxygen across the range of minute volume.

The Target Pressure is further modified slowly (over hours of operation)by the product output purity. This modifier is called “O₂ Factor”. Seestep 304 in FIG. 19. The O₂ factor has a minimum of 1, so that theinitial default target pressure cannot be reduced (as a safeguardagainst purity sensor drift). In step 302, the pressure can, however, beincreased by an increased O₂ factor, if the purity consistently runsbelow the target purity, e.g. 88%, for a long period of time. This isdone, for example, to allow for long term degradation of the sieve dueto water loading. As shown in step 306, a proportional integral controlloop is used to maintain this target pressure in the product tank on atime averaged basis. The compressor motor is sped up (slowly through alow pass filter, as indicated in step 308) to create a higher producttank pressure, and slowed if the pressure is higher than target. Asillustrated in step 310, PWM is used to control the speed, which themotor sees as changing voltage.

Because there is a low pass filter on the PWM, the power provided to themotor stays relatively fixed through the sieve bed cycle. Therefore, asthe bed pressure rises through the cycle, the compressor is allowed toslow down due to the increased pressure load (torque). This, in turn,leads to less fluctuation in the required power than would be seen if afixed speed (rpm) were targeted. The higher power would be the result ofworking harder to maintain a fixed rpm under increasing pressure load.The resulting lower power fluctuation means lower peak battery current,which leads to increased battery life (duration).

The PWM, which is calculated to maintain product tank pressure, ismodified by changes to the system voltage. Thus, if the PWM is setperfectly with batteries that are at ¼ charge (˜13 volts), and the ACexternal power source (18V) is plugged in, the motor speed remains thesame with only a slight jump, instead of a large increase and subsequentslow decrease.

The present invention contemplates, but does not require, using theoxygen purity monitored by oxygen sensor 118 to control the speed of themotor. Changes in the oxygen purity may be affected by the condition ofthe sieve material within the sieve beds 12, the temperature and/or thehumidity of the ambient air being drawn into the apparatus 10 to chargethe sieve beds, and the like. Controller 22 may have a set target oxygenpurity stored in memory, e.g., between about 85-93%, such as 88%, andmay monitor the purity detected by oxygen sensor 118. If the oxygenpurity decreases below the target oxygen purity, controller 22 mayincrease the target reservoir pressure to compensate and increase theoxygen purity. This may trigger the controller increasing PWM based uponthe control loop used by the controller to maintain the new targetreservoir pressure.

Thus, controller 22 may modify PWM, i.e., the speed of motor 40 of thecompressor 14, to maintain the reservoir near its target pressure, whichthe controller may modify based upon the parameters monitored by thecontroller.

The maximum oxygen production rate is dependent upon the speed ofcompressor 14, which, in turn, is dependent upon the input voltage frombatteries 148. To operate effectively, it is desirable for apparatus 10to operate at or close to the target parameters, even as the batteriesbegin to deplete their charges. For a 4S4P Li-Ion battery, the voltageat the end of the battery's charge may be about eleven Volts (11 V).When this battery is fresh (or when apparatus 10 is connected to anexternal power source), by comparison, the voltage may be as much as16.8 Volts. To prevent excess oxygen generation when batteries 148 arefully charged, it may be desirable to impose a maximum speed forcompressor 14, e.g., not more than about 2,500 rpm. Alternatively,controller 22 may allow this maximum speed to be occasionally exceedingwithin a predetermined margin of safety, in order to reduce the risk ofdamage to compressor 14.

By way of example, for an apparatus delivering up to sixty milliliters(60 ml) per breath, an exemplary flow rate of about eight liters perminute (8 lpm, or about 133 ml/s.) may be used. The equivalent volume of88% oxygen gas is about seventy milliliters (70 ml), and the pulseduration would be about 0.53 second. If the apparatus is capable ofgenerating up to about 1200 ml/min, the maximum breathing rate atmaximum dose setting would be about seventeen (17) breaths per minute.Assuming an I:E ratio of 1:2 and that the first fifty percent (50%) ofeach of the user's breaths are functional (and not filling dead-space),the minimum available time would be 0.60 second. At higher breathingrates, the maximum pulse volume (and pulse duration) would be lowerbecause of the maximum production rate.

Because apparatus 10 may operate at relatively low pressures, e.g.,between about five and twelve pounds per square inch (5-12 psi), theflow through any controlling passage within the apparatus will not besonic. Consequently, if the back pressure of apparatus 10 varies, e.g.,due to the cannula or tubing connected by the user, it may cause changesin the flow rate of oxygen delivered to the user. At eight liters perminute (8 lpm), the resistance of cannula may be between about 0.7 andtwo pounds per square inch (0.7-2 psi), e.g., for a Hudson cannula or aTTO catheter was approximately. This increased back pressure may reducethe flow rate of oxygen delivered to the user by as much as twenty fivepercent (25%).

To allow for variance in both reservoir pressure and downstream pressure(pressure from reservoir 18 to the user via the cannula), the followingalgorithm may be employed. The valve “on time” may be adjusted tomaintain a fixed pulse volume (as set by the selected dose setting). Thereservoir pressure may be measured during the time that oxygen deliveryvalve 166 is off, and the pressure across oxygen delivery valve 116 maybe measured, e.g., using pressure sensor 120, while the oxygen deliveryvalve 116 is open.

Valve On Time or the pulse duration (Time Delivery in Table 2) may beset as a factor of dose setting adjusted by oxygen purity to get actualvolume, reservoir pressure, and pressure drop across oxygen deliveryvalve 116. The equations that may be used for these calculations areshown in Table 2, which includes exemplary control parameters that maybe used to operate apparatus 10.

TABLE 2 Start Parameter Type Units Range Value Definition TimePressurize Calc. sec  4-12 6 Pressure Product PsiF × Time PressurizeGain + Time Pressurize Offset. This parameter may be calculated fromTarget pressure instead of measured. Shorter time creates lowerpressure. Time Pressurize Set sec/psi   0-(−.6) −0.3 Gain TimePressurize Set sec  0-20 9 Offset Time Overlap Set sec 0-2 0.2 ReservoirMeas PSI  0-15 8 Measured from Product Pressure Trans. from sensor 114in reservoir with oxygen delivery valve 116 closed. Pressure Calc PSI 0-15 8 Controller 22 may include a Product low pass filter with a timeconstant about thirty seconds (30 sec) to filter out breath and cyclevariations. Pressure Valve Meas PSI  0-15 Measured from Product PsiTrans. using sensor 114 with oxygen delivery valve 116 open. Themeasurement may be delayed after oxygen delivery valve 116 is opened,e.g., at least about 100 ms to avoid artifact. Pressure Valve Calc PSI 0-15 7 Controller 22 may include a PsiF low pass filter, e.g., with atime constant of about 100 ms, to filter out noise. O₂ Percent Meas21-96 Measured from oxygen sensor 118. O₂ Percent F Calc 21-96 80 Thecontroller may include a low pass filter, e.g., with a time constant ofabout 30 s., to eliminate cycle variations. O₂ Percent Set 75-92 ControlAlgorithm Target O₂ Target Percent (resolution .01) Pulse Vol ml Set ml10-60 Set by patient, equivalent dose of 100% O₂ gas Pulse Vol Act Calcml 11-80 Actual Delivered Volume = 79/ ml (O₂ PercentTarget − 21) ×PulseVolml could use O₂Percent instead of Target; but may be lessstable, as volume will go up as % goes down, which in turn could cause %to decrease further Time Resp Sec Meas sec 1-5 Measured time betweenlast two breaths Time Resp Sec F Calc sec 1.5-5   3 Low pass filtered5-10 breaths Production Vol Calc ml/min   0-1500 Pulse Vol. ml × 60/Timeml Resp. Sec F Pressure Calc PSI  3-12 (Pressure Product Target Gain ×Production Product Target Vol. ml + Pressure Psi Product Target Offset)× O₂ Factor Pressure Set PSI/mL/min   0-.03 0.01 Product Target GainPressure Set PSI  0-12 3 Product Target Offset O₂ Factor Calc none .5-1.5 1 02 Factor (old value) × (O₂ Percent Target − O₂ Percent F) ×O₂ Factor Gain O₂ Factor Gain Set none Depends on how often updated, butshould change gradually, over 1-20 minutes Motor Pwm Calc min-100 MotorPwm (old value) × (Pressure Product Psi F − Pressure Product Target Psi)× Motor Pwm Gain. Closed loop control to obtain PressureProductTargetPSIMotor Pwm Set  0-50 50 Minimum and startup PWM Min value, to avoidnon-rotating pump Motor Pwm Set Sets how rapid motor control Gainchanges are - depends on how often updated - control may change somewhatrapidly, because product pressure is already filtered. Time DeliveryCalc Msec 100-700 (Pulse Vol Act ml × Pressure Msec Valve Psi F″ 0.5 ×Time Delivery Gain)/((Pressure Product Psi + 14.2). Time to hold thedelivery valve open- needs more empirical validation Time Delivery Setnone  50-200 100 Gain

In an alternative embodiment, a valve (not shown) is provided that actssimilar to a pressure regulator. Instead of controlling the downstreamgauge pressure, it controls a pressure drop across an orifice placedinline downstream with the delivery valve. In this way, regardless theof downstream pressure, the same flow rate may be delivered, and theresulting volume at a selected pulse duration may be substantiallyconstant.

When a user decides to turn off or shut down apparatus 10, e.g., bydepressing an on/off switch or depressing a “button” on a touch screen,e.g., on user interface 144, it may desirable for the apparatus tocomplete a procedure automatically to protect the apparatus. Forexample, if pressurized air remains in sieve beds 12 after shutdown,water in the air may condense or otherwise be absorbed by the sievematerial, which may damage the sieve material. It may also be desirableto substantially isolate sieve beds 12 from atmospheric conditions,e.g., to prevent the sieve beds from “breathing” when apparatus 10encounters changing barometric pressure and/or temperature. Any suchbreathing may introduce air into or evacuate air out of the sieve beds,which may introduce moisture into the sieve material.

When apparatus 10 is being turned off, oxygen delivery valve 116 may beclosed to discontinue delivery of oxygen from reservoir 18. Supply aircontrol valves 20 _(s) may be automatically closed (either actively oras the default when electrical power is turned off), e.g., while exhaustair control valves 20 _(e) are opened. After a first predetermined time,e.g., between about one hundred and thee hundred milliseconds (100-300ms), compressor 14 may be turned off. Leaving compressor 14 operatingmomentarily after closing supply air control valves 20 _(s) may leaveresidual pressure within the manifold 16, which may enhance holding thecontrol valves 20 _(s) closed for an extended period of time. Thispressure may leak slowly over time.

After a second predetermined time, e.g., between about nine and twelveseconds (9-12 sec), allowing any pressurized air to be exhausted fromsieve beds 12, the exhaust air control valves 20 _(e) may be closed(either actively or as the default when electrical power is turned off).

H. Carrying Bag

The overall external appearance of apparatus 10 is best shown in FIGS.1A and 1B. The bottom exterior surface is defined by air manifold 16,the opposing top exterior surface is defined by oxygen manifold 102, theexterior surface of one end portion is defined by side panels 59, 159,the exterior surface of the opposing other end portion is defined bysieve beds 12 and reservoir 18, the exterior surface of one side portionis defined by a panel 200, and the exterior surface of the opposingother side portion is defined by a panel 202. In an exemplaryembodiment, panels 200 and 202 are relatively thin sheets of material,such as plastic or metal. Their primary purpose is to enclose theinternal volume of the apparatus. However, the can all provide structuresupport for the device. The present invention also contemplates thatthese panels can be omitted entirely.

It can be appreciated that the external appearance of the apparatus aspresented by the above-noted components is not aesthetically pleasing,provides little protection for the apparatus, and does little to helpreduce the sound generated by the apparatus. To accomplish these, andother functions, the present invention contemplates providing a carryingbag 210 to house apparatus 10. The carry bag eliminates the need for,and weight of, an external plastic enclosure typical of conventionalportable oxygen concentrators.

An example of a carrying bag 210 suitable for this purpose is shown inFIGS. 21-23. Bag 210 is made from a light-weight material, such aspolyester with a PVC coating, that has a shape generally correspondingto the shape of apparatus 10 and completely encapsulates the apparatus.The material, or combination of materials, is selected so as to bedurable, light weight, stain resistant, water resistant, or anycombination thereof.

The present invention contemplates that apparatus 10 and bag 210 aresecured together so that the apparatus be easily removed from the back.For example, screws, bolts, or other fasteners can be used to join thebag to the oxygen conserver apparatus. This allows a technician, forexample, to disassemble the bag from the apparatus, but will make itdifficult for a user to remove the apparatus from the bag, as well asprevent the apparatus from accidentally falling or slipping out of thebag. In this way, the bag is an integral part of the entire oxygenconserver apparatus.

Bag 210 has a generally rectangular shape to match the shape ofapparatus 10. However, there is no requirement that the shape of the bagmatch that of the concentrator it is housing. Bag 210 includes a toppanel or flap 212 that is at least partially separable from theremainder of the bag to allow access to the interior of the bag. In theillustrated embodiment, a zipper 214 is provided around a portion of theperimeter of the bag to allow top panel 212 to be opened, as shown inFIG. 23, or closed, as shown FIGS. 21 and 22. It is through this accessthat the apparatus is placed into and removed from the bag. The presentinvention contemplates providing a lock on zipper 214 so that the toppanel cannot be opened without authorization.

Top panel 212 includes a transparent panel 216 that overlies touchscreen display 230 when the top panel is closed. This transparent panelis sufficiently flexible so that the user can operate the touch screenuser interface through this panel. Transparent panel 216 is also madefrom a water resistant, durable material so that it can effectivelyprotect the touch screen without impeding its use. Top panel alsoincludes a cannula barb access port 218 so that cannula barb 139 extendsthrough the bag wall. In an exemplary embodiment, a flexible material,such as neoprene, is provided around cannula barb access port 218 toprevent water ingress and allow flexibility in the position of thecannula barb through the wall of the bag.

To access battery opening 140 a and/or 140 b a battery slot 220 is alsoprovided in top panel 212. A battery slot flap 222 covers battery slot220 and is held in the closed position via a fastening mechanism, suchas a hook and loop fastener, zipper, snap, or the like. Moving batteryslot flap 222 provides access to battery slot 220 so that a battery canbe provided or removed from the battery slot. Although only one batteryslot 220 and battery slot flap 222 is shown in bag 200, it is to beunderstood, that the second battery opening can also be accessed andcovered by a similar system. If, however, only one battery slot isprovided, the second battery opening is accessed by opening top panel212, as shown in FIG. 23.

The end wall of bag 210 includes one or more inlet cutouts 226 thatoverlie inlet opening 160 a, 160 b when apparatus 10 is disposed in thebag. A mesh or other screen 228 is provided in inlet cutouts 226 toprevent large materials from entering inlet opening 160 a, 160 b. In anexemplary embodiment, a filter housing pocket is also provided overinlet cutouts 226 either on the inside, the outside of the bag, or bothfor holding a disposable filter over inlet opening 160 a, 160 b. In afurther embodiment, the bag is configured such that the path the flow ofair must follow in order to reach inlet opening 160 a, 160 b is atortuous path and is open in a downward direction to prevent wateregress into the interior of the bag.

The present invention further contemplates that bag 200 includes acarrying handle or strap 224 that is affixed to or detachable from thebag. The bag also includes pockets 232. The number, size, location, andconfiguration of the pockets, handles, or straps can be varied in anymanner to suit the needs of the user, including providing internalpockets or recesses.

Bumpers or other spacers can be provided on one or more of the interiorsurfaces of the wall of the bag. Optionally, bag 200 may include paddingor other sound absorption materials to help minimized the sound outsidethe bag. In other words, the bag itself can be made from or packed witha sound attenuating material or can include sound attenuating materialsat strategic locations to keep sound levels to a minimum. In addition,foam pads or other supporting/shock absorbing material can be providedat the bottom of the interior of the bag or at other locations in thebag to support apparatus 10. In an exemplary embodiment, relatively highdensity foam pads are provided at each lower corner of the bag forprotecting apparatus 10 and lower density foam material is usedelsewhere to minimize weight. In addition, the bottom of the bag can beprovided with a high strength, water impervious material, such asrubber, to protect the bottom of the bag, which is expected toexperience the greatest wear and tear.

I. Touch Screen User Interface

FIGS. 24-32 illustrate the displays, i.e., visual information, providedon user interface 144 during use of apparatus 10. More specifically,these figures illustrated the information provided on touch screen 230.When the device is off, the display is blank. When touch screen 230 istouched once, an on/off icon 240 is presented, as shown in FIG. 24.Activating the apparatus requires touching on/off icon 240, causing thesystem to advance to an active state. Touching other locations of thetouch screen will not start the apparatus. Thus, activating the devicerequires two touches on the touch screen, with the second touch being ata specific location on the touch screen. This “double touch” feature ofthe present invention prevents unwanted or inadvertent activation of theapparatus.

Once activated, the system may display predefined information, such as acorporate logo, advertisements, user instructions, diagnosticinformation, error information, usage information, and the like. FIG. 25illustrates information that may be provided on the touch screen atstart-up. As shown in FIG. 25, touch screen 230 includes fields 242 thatindicates the version of software currently being run by the apparatus,a field 246 that indicates the number of hours the apparatus has beenused, and a field 248 that indicates any error codes, i.e., errors thatmay have been detected during a diagnostic process, which could havebeen conducted earlier and/or during startup of the device.

FIG. 26 illustrates the information provided on a typical touch screen230 after apparatus 10 is turned on. As shown in this figure, touchscreen 230 includes on/off icon 240, a pulse dose or flow settingindication 250, which is the numeral “1” in the illustrated embodiment,and a battery icon 252. It can be appreciated that the size of flowsetting indication 250 is relatively large, i.e., large enough to occupy20-80% of the entire touch screen. This enables the user to easilyvisually discern the flow setting. In an exemplary embodiment of thepresent invention, the actual height of the flow setting icon is atleast one half inch and the actual width is at least one quarter inch.In an exemplary embodiment, the height is at least 1.25 inch and thewidth of each digit is one half inch or greater. In addition, in anexemplary embodiment, battery icon 252 is at least o½ inch wide and atleast ¾ inch tall.

Battery icon 252 is a solid battery shaped image that indicates that theprimary battery is inserted into battery opening 140 a and the batteryis fully charged. It is to be understood that if a secondary battery isinserted into secondary battery opening 140 b, a second battery icon isdisplayed on the other side of touch screen 230 (see, e.g., FIG. 28).This enables the user to quickly and easily determine what batteries areinserted into the battery openings and the amount of life left in eachbattery.

FIG. 27 illustrates battery icon 252 in a format that shows the amountof energy remaining in(or removed from) the battery. In this embodiment,the battery icon has a right field 260 and a left field 262. Thesefields are used to provide more detailed information about the battery.For example, in this embodiment, right field 260 indicates the amount ofcharge (e.g., 75% in the illustrated embodiment), and left field 262indicates whether the battery is charging. In the illustratedembodiment, the vertical bar is scrolled or animated in some fashion toindicate that battery charging is taking place. An AC power icon 266 isalso shown on touch screen 230 to show that the apparatus is connectedto an AC power source.

FIG. 28 illustrates a typical display that shows that two batteries areinserted into the battery openings as indicated by batter icons 252 aand 252 b. It can be appreciated from this display that the secondarybattery in battery opening 140 b is fully charged (left battery icon 252b) and the primary battery in battery opening 140 a is nearly empty(right battery icon 252 a) and is charging. Touch screen 230 alsoincludes a DC power icon 270 that indicates whether the apparatus isconnected to a DC power supply, such as that available via a caradapter.

To change the flow setting, the user must first press flow settingindication 250. After a short period of time, e.g., 2-6 seconds, flowsetting change icons 272 and/or 274 are displayed, examples of which areshown in FIGS. 29 and 30. Note that only one flow setting change icon isshown in FIG. 29, because “1” is the lowest flow setting so that theflow setting can only be increased, not decreased. Actuating the flowsetting change icon will cause the apparatus to change the output flow.The new flow setting is displayed. The flow setting change icons willremain on the screen for a short period of time, e.g., 2-6 seconds, oruntil the flow setting indication 250 is pressed again.

As noted above, apparatus 10 includes the ability to sound alarms orother warnings if a monitored variable exceeds a threshold. FIGS. 31 and32 illustrate and example of the appearance of touch screen 230 when analarm condition is detected. Upon detecting an alarm occurs, an alarmicon 276 indicating the nature of the alarm is displayed on the touchscreen. Note that the size of flow setting indication 250 has beenreduced to better show the alarm icon. In the illustrated embodiment,the alarm condition is the failure to detect a user's breath. This canoccur, for example, if the user ceases using the device.

An audible alarm icon 278 is also provided if the alarm condition issuch that it causes an audible warning to be provided. Audible alarmicon 278 is used to turn the audible alarm on an off by simply touchingthat icon. In FIG. 31, the audible alarm is on, and, in FIG. 32, theaudible alarm is silenced.

FIG. 33 is a chart illustrating the alarm icons that are provided ontouch screen 230. The following is a brief discussion of each alarmcondition listed in this chart.

NO BREATH ALARM—This alarm occurs when a breath is not detected for aperiod of 30 seconds or more. This alarm will become silent as soon as abreath is detected. If no breath is detected after approximately 5minutes, the unit will shut down to conserve power.

OXYGEN CONCENTRATION ALARM—This alarm occurs when apparatus 10 is notdelivering the concentration of oxygen that is specified.

HIGH BREATH RATE ALARM—This alarm is a notification that the user'sbreath rate is starting to exceed the capacity of the apparatus. Thealarm will reset itself when breath rate is reduced.

TECHNICAL FAULT/GENERAL MALFUNCTION ALARM—The device shuts down whenthis alarm occurs. This alarm occurs when the battery runs out or thedevice has a general malfunction and the unit is no longer operatingproperly.

AUDIBLE ALARM ICON—This icon appears when an audible alarm occurs. Pressthis icon to silence the audible alarm.

ALARM SILENCE ICON—This icon appears when the user presses the audiblealarm icon in order to silence the audible alarm.

BATTERY LOW ALARM—Battery icon(s) flashes when approximately 17 minutesof battery life remain.

BATTERY DEPLETED ALARM—Indicates approximately 2 minutes of battery liferemain.

It can be appreciated that the present invention is not intended to belimited to the icons and fields shown in the figures and/or describedherein. Other information can be provided in virtually any format,including animation and sounds. In addition, combinations of informationcan be provided. By providing a large amount of functionality using asingle touch screen display, the present invention avoids the need forseparate or dedicated input/output devices. For example, followingdevices are typically used in a conventional oxygen concentrator and canbe eliminated in the present invention in favor of using touch screen230 to accomplish each of their functions: an on/off switch, a flowsetting knob, a flow setting indication (flow meter or digitalindicator), operating status/alarm LEDs, and power and/or batteryindicators.

The present invention also contemplates providing hidden icons on touchscreen 230 that can be activated to access functions that should only beperformed by someone with authorization to do so, such as a technician.For example, a portion of touch screen 230 that is not designated by anyicon may becomes active during start-up. Pressing that portion of thescreen provides access to a service/setup menu that allows the user toperform advanced features, such as calibrating the oxygen sensor.

J. Performance Comparison

Apparatus 10 has several features that enable it to provide betterperformance in terms of oxygen output than conventional portable oxygenconcentrators, such that the AirSep Lifestyle and Inogen concentrators,for a given size, size, weight and sound level. For example, apparatus10 includes a high output, high-efficiency 3-head radial aircompressor/motor that in an exemplary embodiment, weights only 516 grams(1.14 lbs). In addition, integrated, light weight components areselected for the other features of the apparatus. The canisters in thesieve beds in an exemplary embodiment have a wall thickness of 0.020inch. In addition, by providing the air manifold and oxygen deliverymanifolds with integrated gas flow paths and having these manifoldsdefine the structural support for other components, the overall numberof components, complexity, size, and weight is minimized. The use of atouch screen in place of traditional discrete user controls minimizessize and weight. In addition, carrying bag 200 helps reduce weight andnoise. The PSA process is optimized for lowest power/highest oxygenoutput (i.e. (a) oxygen concentration reduced to 88%, (b) varying thecycle times limit peak pressure to just 12 psig). The use of twointernal batteries also allows apparatus 10 a relatively large portablepower supply.

The result of these design optimizations the portable oxygenconcentrator of the present invention has performance capabilitiesbeyond that of conventional portable oxygen concentrator. FIG. 34 is atable that lists the features of the present invention using twobatteries as compared to four other conventional devices advertised asbeing portable oxygen concentrators.

One interesting parameter that can be deducted from the chart shown inFIG. 34 is the ratio of the oxygen generation and battery life to thetotal weight of the unit. This parameter is determined as follows:R _(ODW)=(O₂output*duration)/total weight,   (4)where O₂ output is the 100% oxygen output, which is determined fromEquation (1) and/or the chart of FIG. 12, duration is the operating lifeof the apparatus for the given amount of batteries, and weight is thetotal weight of the unit including all components. Table 3 belowprovides the R_(ODW) for the apparatus of the present invention using 1,2, or 3 batteries (each weighing 1.5 lbs) and existing portable oxygenconcentrators.

TABLE 3 100% Equivalent Duration Weight R_(ODW) O₂ Output (lpm) (hours)(lbs) (lpm-hr)/lb Present Invention 0.9 4 8.3 0.43 (1 battery) PresentInvention 0.9 8 9.8 0.73 (2 batteries) Present Invention 0.9 12 11.30.95 (3 batteries) Inogen 0.65 3 9.7 0.20 AirSep LifeStyle 0.6 0.83 9.80.05 AirSep FreeStyle 0.36 2.5 4.4 0.20 AirSep FreeStyle 0.36 6.0 6.20.35 w/ battery belt SeQual 2.65 2.0 17.4 0.30For the Inogen, AirSep LifeStyle, and Airsep Freestyle devices, the O₂output is estimated based on measurements of the operation of the deviceand/or a similar device converted to a 100% oxygen equivalent, which isshown in FIG. 34. For example, for the Sequal device, the oxygen outputhas to be converted to a 100% oxygen equivalent using the correctionfactors from Equation (1) and/or the chart shown in FIG. 12. Morespecifically, the SeQual device has an output of 3.0 Imp at 91% oxygenpurity. Converting this to a 100% purity equivalent is done as follows:3.0/1.13 (1.13 is selected from FIG. 12 using a 91% purity level), toyield a 100% purity equivalent of 2.65 lpm.

It can be appreciated from Table 3 that the apparatus of the presentinvention has a much greater R_(ODW) than that of existing devices. Thismeans that, as compared to other portable oxygen concentrators, theapparatus of the present invention is very efficient in terms of theactual overall mass of the product and its ability to generate oxygen.For each pound of the apparatus, the oxygen concentrator of the presentinvention provides a higher flow of oxygen for a longer period of timethan existing devices.

K. Sound Versus Battery Life

FIG. 35 is a chart illustrating various performance criteria forapparatus 10 using two batteries at different pulse settings. It can beappreciated from reviewing this figure that the apparatus of the presentinvention has a long operating life and accomplishes this at soundlevels that are relatively low. For example, the device of the presentinvention lasts a least 10 hours at a dB level less than 50. The chartalso clearly demonstrates the relationship between the pulse settingsand the performance of the apparatus, such as the minute volume ofoxygen, the oxygen concentration, gas bolus size delivered during each,sound, power, and battery life. In this chart, the “maximum” battery runtime is the theoretical maximum of the battery, and the “nominal”battery run time is the typical or published run time that can beroutinely achieved under normal operating conditions.

To better understand how the combination of operating life (duration)and sound in the present invention are superior to that of existingdevices, consider the ratio of duration to sound (R_(DS)), which isdefined as duration/sound level. Table 4 below summaries the R_(DS) ofthe present invention and that of existing portable oxygenconcentrators.

TABLE 4 Duration R_(DS) (hours) Sound (dB) (duration/sound) PresentInvention 4 55 0.073 (1 battery) Present Invention 8 55 0.145 (2batteries) Present Invention 12 55 0.218 (3 batteries) Inogen 3 35.20.085 AirSep LifeStyle 0.93 55 0.017 AirSep FreeStyle 2.5 55 0.045AirSep FreeStyle 6 55 0.090 (w/ battery pack) SeQual 1.41 48 0.024It can be appreciated the present invention using two batteries providesa duration to sound ratio that is significantly higher than existingdevices.

L. Weight Optimization

It is axiomatic that the size of the battery contributes to both thetotal weight and the operating duration of the portable oxygenconcentrator. The more battery size that is added to the apparatus thelonger the unit will operate, which is a desirable feature. However,adding batteries to the apparatus will cause it to weigh more, which isnot a desirable feature. The portable oxygen concentrator of the presentinvention has the ability to operate using one or two batteries,allowing the user to determine how much weight to add for the desiredamount of operating time.

In an exemplary embodiment, the weight of each battery is approximately1.5 lbs. The weight of the apparatus without any batteries isapproximately 7.8 lb. With one battery used in the apparatus, the totalweight of the portable oxygen concentrator is approximately 8.3 lb. Itcan thus be appreciated that with one batter, the weight of the batteryalone represents approximately 17.6% of the total weight of theapparatus.

With two batteries used in the apparatus, the total weight of theportable oxygen concentrator is approximately 9.8 lbs. It can thus beappreciated that with two batteries, the weight of the batteries alonerepresents approximately 30.6% of the total weight of the apparatus.Table 5 below summarizes the information provided above, in addition toshowing how additional 1.5 lb battery packs contribute to the totalweight of the apparatus.

TABLE 5 Percent Total Weight Percent Total of all Number Total WeightTotal Weight of Weight Non-Battery of of Batteries Apparatus with Due toComponents Batteries (lbs) Batteries (lbs) Batteries (%) (%) 0 0 6.8 0.0100.0 1 1.5 8.3 17.6 82.4 2 3.0 9.8 30.6 69.4 3 4.5 11.3 39.8 60.2 4 6.012.8 46.8 53.2

It can be appreciated from reviewing Table 5 that the portable oxygenconcentrator of the present invention is capable of providing arelatively high output of oxygen (0.90 lpm) for a duration of at leasteight hours and the total battery weight is only 30.6% of the totalweight of the system.

In a conventional portable oxygen concentrator, the weight of thecompressor typically contributes to a relatively large percentage of thetotal weight of the system. The compressor described above provides ahigh output at a relatively small weight. Table 6 below shows how theweight of the compressor contributes to the total weight of the system.

TABLE 6 Percent Total Weight Total Weight Percent Total of all Non-Number Weight of of Apparatus Weight of the Compressor of Compressorwith Batteries Compressor Components Batteries (lbs) (lbs) (%) (%) 01.14 6.8 16.8 83.2 1 1.14 8.3 13.8 86.2 2 1.14 9.8 11.6 88.4 3 1.14 11.310.1 89.9 4 1.14 12.8 8.9 91.1

M. Oxygen Conserving Devices

In the embodiments described above, a single lumen cannula is used todeliver the flow of gas to the user. This same cannula is used to sensethe changes in pressure and/or flow so that the device can detect whento deliver the bolus of oxygen. Based on the pressure measured bypressure sensor 122, controller 22 causes oxygen delivery valve 116 tocontrol the flow of gas so that it is delivered to the patient onlyduring the inspiratory phase of the respiratory cycle. This is anexample of an electronic conserver, which is built into apparatus 10.

The present invention further contemplates that the electronic pressuresensor and electronic valve can be replaced with a single lumenpneumatic oxygen conserving device. A pneumatic oxygen conserving devicehas the advantage in that it does not require electrical energy to causethe gas flow to be delivered only during inspiration, thus savingbattery life. Examples of pneumatic oxygen conserving devices suitablefor use in the present invention are disclosed in U.S. Pat. Nos.5,881,725; 6,484,721; 6,568,391; and 6,752,152, the contents of each orwhich are incorporated herein by reference.

The present invention contemplates that a dual lumen cannula system canbe used in place of the single lumen system described above with respectto the pneumatic oxygen conserving device. In a dual lumen pneumaticsystem, one lumen in the cannula is used to deliver gas to the patientand the other lumen is in fluid communication with the airway, such asthe nares, to sense gas flow and/or pressure of the user. A flow and/orpressure sensor is coupled to the other end of the cannula. In thisembodiment, a second prong or barb would be needed on apparatus 10 and aflow sensor, pressure sensor, or both are coupled to the second barb.

The present invention further contemplates that the oxygen conservingfunction can be provided in a separate oxygen conserving device,electronic or pneumatic, that is not attached to oxygen concentrationsystem 10. In other words, an electronic or pneumatic oxygen conservercan be provided at a location external or not integral with apparatus10. In FIG. 36, a oxygen concentration system 500 is shown that includesan oxygen concentrator 10 contained in a housing and an electronic orpneumatic oxygen conserver 502 that is physically spaced apart from thehousing of the oxygen concentrator. The oxygen conserver can includefasteners, straps, clips or other devices to enable the oxygen conserverto be attached to the user, to bag 210, and or a part of the bag, suchas the carrying strap 224. In this illustrated exemplary embodiment, alength of cannula 504 separates oxygen conserver 502 from oxygenconcentration system 500. Another annular 506 communicates gas fromoxygen conserver 502 to the user (not shown). Oxygen concentrationsystem 10 can be provided in a carrying bag 210, if desired. Thisconfiguration for the oxygen concentration system of the presentinvention avoids the extra weight, complexity, and power consumptionfrom being included in apparatus 10.

The separate oxygen conserver can also be a modular device that attachesto apparatus 10 and/or carrying case 210 when desired. FIG. 37illustrates an oxygen concentration system 510 in which an oxygenconserver 512 is selectively attachable to apparatus 10. For example,oxygen conserver 512 can include a recess for receiving barb 139 andmechanisms can be provided to join the oxygen conserver to apparatus 10such that they can be separated from one another. In the illustratedembodiment, a carrying bag 514 is provided that encapsulates both oxygenconcentration system 510 and oxygen conserver 512, with a cannula 516extending from the bag.

FIG. 38 illustrates an oxygen concentration system 520 in which anoxygen conserver 522 is selectively attachable to apparatus 10 and iscontained in a carrying bag 524 that also contains apparatus 10. In theembodiment, carrying bag 524 includes a first chamber 526 that housingapparatus 10 and a second chamber or pocket 528 that houses oxygenconserver 522. This allows the user to leave pocket 528 empty or usedfor other purposes if oxygen conserver 522 is not needed. A jumpercannula 530 or other pneumatic connection is provided to connected theoutlet of the oxygen concentration system with the inlet of the oxygenconserver. A delivery cannula 532 is provided to communicate the oxygenenriched gas from oxygen conserver 522 to the user.

N. Use In a Liquefaction or Trans-Fill System

The present invention contemplates using apparatus 10 as part of or incombination with other types of oxygen generation/delivery systems. Forexample, apparatus 10 can be used in a liquefaction system, which is asystem that produces liquid oxygen for user consumption. As shown inFIG. 39, a typical liquefaction system 550 includes an oxygenconcentrator 10 that provides gas for liquefying to a cryogenic coolingsystem 552, which lowers the temperature of the gas level that causesthe oxygen to change state from a gas to a liquid. The liquid oxygen canbe stored in a storage vessel 554, typically referred to as a dewer,that is easily transported by the user. The user can breathe gaseousoxygen from the storage vessel as indicated by arrow 556, from theoutput of the oxygen concentrator as indicated by arrow 558, or both.This enables the user to have a supply of liquid oxygen fortransportation and consumption.

An optional valve can be provided to control the flow of oxygen enrichedgas to the user or the cryogenic cooling system 552 so that the gas isdelivered to one or the other or to both simultaneously. In addition, aninternal dewer can be provided in the liquefaction system to allow thesystem to generate liquid oxygen even when the portable dewer is notattached to the system. Liquid oxygen from the internal dewer can beprovided to the portable dewer when the portable dewer is connected tothe liquefaction system. Examples of liquefaction systems suitable foruse in the present invention are described in U.S. Pat. Nos. 5,893,275;5,979,440; 6,212,904; 6,314,957; 6,651,653; 6,681,764; and 6,698,423,the contents of each of which are expressly incorporated herein byreference.

The features of apparatus 10, such as the compressor, sieve beds, andoperation can be incorporated into the liquefaction system such that theoxygen concentrator and the components of the liquefaction system, suchas the refrigeration system, are combined into a common device. Becauseapparatus 10 of the present invention provides a lightweightconcentrator with a relatively high oxygen flow output and long durationbattery life, the inclusion of the apparatus 10 in a liquefaction systemprovides a liquefaction system that is capable of being ambulatory,i.e., transported by a user, and operated without an AC power supply.The present invention also contemplates that apparatus 10 can beseparate from the rest of the liquefaction system. This enables eachcomponent of the liquefaction system to be more easily transportedindividually.

Apparatus 10 can also be used in a transfill system 580 as schematicallyillustrated in FIG. 40. A transfill system is a system that compresses agas, such as concentrated oxygen, and provides the compressed gas tostorage vessel, such as a portable oxygen tank. In a typical transfillsystem, oxygen from an oxygen concentrator 10 is provided to acompressor 582, such as a piston compressor, where it is compressed to arelatively high pressure, e.g., from 1500 to 3500 psi. The compressedgas is provided to a portable storage vessel 584 that is capable ofbeing carried or otherwise transported by the user. The user can breathegaseous oxygen from storage vessel 584 as indicated by arrow 586, fromthe output of the oxygen concentrator (apparatus 10) as indicated byarrow 588, or both. This enables the user to have a supply of highpressure oxygen for transportation and consumption.

An optional valve can be provided to control the flow of oxygen enrichedgas to the user or to the compressor 582 so that the gas is delivered toone or the other or to both simultaneously. In addition, an internalstorage vessel can be provided in the transfill system to allow thesystem to produce high pressure oxygen enriched gas even when theportable storage vessel is not attached to the system. High pressureoxygen enriched gas from the internal storage vessel can be provided tothe portable storage vessel when the portable storage vessel isconnected to the transfill. Examples of transfill systems for use in thepresent invention are described in U.S. Pat. Nos. 5,071,453; 5,354,361;5,858,062; 5,988,165; 6,302,107; 6,446,630; 6,889,726; 6,904,913, and6,923,180 and in European Patent Application No. 0 247 365 A2, thecontents of each of which are expressly incorporated herein byreference.

The features of apparatus 10, such as the compressor, sieve beds, andoperation, can be incorporated into the transfill system such that theoxygen concentrator and the components of the transfill system, such asthe high pressure compressor, are combined into a common device. Becauseapparatus 10 of the present invention provides a lightweightconcentrator with a relatively high oxygen flow output and long durationbattery life, the inclusion of the apparatus 10 in a transfill systemprovides a transfill system that is capable of being ambulatory, i.e.,transported by a user, and operated without an AC power supply. Thepresent invention also contemplates that apparatus 10 can be separatefrom the rest of the transfill system. This enables each component ofthe transfill system to be more easily transported individually.

O. Sound Reduction

In order to make apparatus 10 as quiet as possible, the presentinvention contemplates several techniques for reducing the soundgenerated by the apparatus. Sound can be generated from differentportions of the portable oxygen concentrator. One such source is theflow of gas into and around the apparatus. To suppress the noise due tothis flow, the present invention contemplates providing baffles inpassages 62-68. Examples of such baffles include protrusion or angledprojections that extend into the passages from the passage walls.

Another source of sound is compressor 14. Sound from the compressor isbelieved to come from sound associated with the movement of the parts ofthe compressor and sound caused by vibration induced by the operation ofthe compressor. To suppress the sound resulting from the movement of theparts of the compressor, the present invention contemplates providing amuffler at or proximate to the inlet of the compressor. The muffler atthe inlet prevents or reduces noise generated within the compressor fromtraveling back up the inlet passage and exiting the compressor inletflow path.

As shown in FIG. 41, the present invention also contemplates providing acompressor jacket 350 that covers or overlies at least a portion of thecompressor. In the illustrated embodiment, compressor jacket 350includes a plurality of panels 352 only one of which is illustratedand/or visible in FIG. 41. Panel 352 is provided on compressor 14 suchthat each panels is disposed between each compressor head 46 andoverlies cam assembly 42, which is shown in FIG. 5A. Panels 352 are madefrom a sound absorbent material and are attached to the compressor,directly or indirectly, using any technique. In the illustratedembodiment, the panels only cover the area between the compressor headto prevent heat build-up. It is to be understood, however, that thesize, shape, and location of the panels can vary. For example, thepresent invention contemplates providing compressor jacket 350 aroundthe entire compressor.

In the illustrated embodiment, compressor 14 is mounted directly to airmanifold 16. This direct mounting of the compressor on the manifold mayimpart vibrations from the compressor to the manifold, which can resultin the generation of noise. To prevent such translation of vibration,the present invention contemplates providing isolators 360 betweencompressor 14 and the manifold (not shown in FIG. 37) to which thecompressor is attached. In an exemplary embodiment, isolators 360 aredefined by a flexible tube, such as rubber, provided at the inlet andoutlet of each compressor head. Vibration that occurs in compressor 14during its operation is prevented from translating to the manifold byisolators 360.

P. Battery Life Optimization

In an exemplary embodiment of the present invention, the portable oxygenconcentrator uses a Li-Ion cell in the battery or batteries,collectively referred to as the battery pack, that provide power to thevarious components of the system. Li-Ion cells have a known dischargerate characteristic, an example of which is shown in FIG. 42. The x-axisis mA-hr or mili-ampere X hours. At 0 mA-hr, the Li-Ion cell has 100%capacity remaining. At 2100 mA-hr, the cell has 0 capacity remaining.Each line 370, 372, 374, and 376 in this figure shows how the voltagedecreases over time (progressively larger mA-hr) at different dischargecurrents. In this chart, current draw is varied by 10× from 0.42-4.2 A.The higher the current draw, the lower the voltage for the same energy(mA-hr) consumed.

In apparatus 10 of the present invention, the current draw from thebattery pack is limited to approximately 4 amps or less during the sievebed pressurization. However, the battery pack has the capability todischarge at 8 amps. By limiting the peak current to 4 A, the effect isto avoid operation on the line 370, and, instead, operate on line 372,e.g., by limiting the current draw to half of the maximum current. Asshown in FIG. 42, lines 372, 374, or 376 are relatively similar, so thatthere is a minimal reduction in run time when the apparatus is operatingin that current range. It is only when the current is increased to line370 that a notable reduction is run time occurs.

The apparatus of the present invention matches the PSA process, andmotor maximum current to the discharge characteristics inherent in aLi-Ion cell, so that the apparatus “squeezes” all of the energy out ofthe battery pack so that the actual run time approaches the maximumtheoretical run time. In addition, when two batteries (cells) are usedin the battery back, the current drawn from each batter is furtherlimited, so that each battery is operating on an even lower currentline, such as lines 374 or 376.

Although the invention has been described in detail for the purpose ofillustration based on what is currently considered to be the mostpractical and preferred embodiments, it is to be understood that suchdetail is solely for that purpose and that the invention is not limitedto the disclosed embodiments, but, on the contrary, is intended to covermodifications and equivalent arrangements that are within the spirit andscope of the appended claims. For example, it is to be understood thatthe present invention contemplates that, to the extent possible, one ormore features of any embodiment can be combined with one or morefeatures of any other embodiment.

1. A portable oxygen concentrator, comprising: (a) a plurality of sievebeds for adsorbing nitrogen from air, the sieve beds comprising airinlet/outlet ends and oxygen inlet/outlet ends; (b) at least onereservoir communicating with the oxygen inlet/outlet ends of the sievebeds for storing oxygen exiting from the oxygen inlet/outlet ends of thesieve beds; and (c) a compressor for delivering air at one or moredesired pressures to the air inlet/outlet ends of the sieve beds, thecompressor comprising: (1) a motor, (2) a crankshaft coupled to themotor defining a central axis, (3) three diaphragm assemblies, eachincluding a flexible diaphragm, spaced apart around the central axis,wherein the diaphragms in three diaphragm assemblies are substantiallycoplanar with one another, and wherein a plane in which the threediaphragm assemblies are located is generally perpendicular to thecentral axis, and (4) three rods extending between respective flexiblediaphragms and the crankshaft, and wherein the three rods are coupled tothe crankshaft such that the three rods are offset axially from oneanother along the central axis.
 2. The portable oxygen concentrator ofclaim 1, further comprising: a set of valves between the compressor andthe air inlet/outlet ends of the sieve beds; and a controller coupled tothe valves for selectively opening and closing the valves to alternatelycharge the sieve beds by delivering compressed air into the sieve bedsthrough the air inlet/outlet ends to cause oxygen to exit from theoxygen inlet/outlet ends into the reservoir and purge the sieve beds byevacuating pressurized nitrogen from the sieve beds through the airinlet/outlet ends, wherein oxygen passes from a sieve bed being chargedto a sieve bed being purged via a purge orifice to assist evacuatingnitrogen from the sieve bed being purged.
 3. The oxygen concentrator ofclaim 1, further comprising an air manifold defining a plurality ofpassages therein communicating with the diaphragm assemblies and the airinlet/outlet ends of the sieve beds.
 4. The oxygen concentrator of claim3, wherein the diaphragm assemblies are mounted directly to the airmanifold.
 5. The oxygen concentrator of claim 1, wherein the compressorweighs not more than about two pounds.